Fluid Power Journal Tech Directory 2014

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FLUID POWER JOURNAL

in THIS

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Accelerate Prototyping With

NUMERICAL SIMULATION

TECH DIRECTORY 2014 | VOLUME 21 | ISSUE 9

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FLUID POWER INNOVATION & RESEARCH CONFERENCE 2014 October 13-16

Is Your AIR COMPRESSOR CONTROL Smarter Than a Four Year Old?

10

13

HYDRAULIC OUTPUT TRIPLED, Manufacturing Headaches Eliminated

Eaton “EDUCATES THE EDUCATORS” at its 2014 Instructor Symposium

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INTERNSHIPS AT MAGNETEK Provide Experience, Opportunity

REPAIRING HYDRAULIC SERVO VALVES in Seismic Vibrator Trucks

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NOTABLE WORDS

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TECH DIRECTORY LISTING

32

TECH DIRECTORY MATRIX

8

ECONOMIC REPORT

27

IFPS NEWS

44

NFPA NEWS

12

AIR TEASER

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WEB MARKETPLACE

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Departments

Publisher’s Note: The information provided in this publication is for informational purposes only. While all efforts have been taken to ensure the technical accuracy of the material enclosed, Fluid Power Journal is not responsible for the availability, accuracy, currency, or reliability of any information, statement, opinion, or advice contained in a third party’s material. Fluid Power Journal will not be liable for any loss or damage caused by reliance on information obtained in this publication.

Fluid Power Journal is the official publication of the International Fluid Power Society

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‰ NOTABLE WORDS

Fluid Power Profitability – THE POWER OF A BUSINESS ACCELERATOR MODEL

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here is untapped profittive dissemination of informaability to uncover for the tion is what enables a supply design and engineering chain to come together in a teams sizing up hydraulic and way that creates a true value pneumatic sealing and bearing chain for all stakeholders. systems for specialized fluid Knowledge flow also creates power applications. This can be value by making the supply especially true for those develchain more transparent and opment engineers who have a by giving involved parties a need for complex total sealing 360-degree view on customer

BY JOE WOODS, FLUID configurations, which often can needs and value propositions.

POWER SEGMENT MANAGER, TRELLEBORG SEALING be analogous with fluid power Increased visibility can proSOLUTIONS vide such benefits as a betapplications. In fact, we have ter understanding of market devised a business accelerator model that gives a strategic perspective on trends, enhanced product design, planning, people, processes, and products using a total and development.

Leveraging an advanced delivery program value assessment to more accurately quantify can result in increased throughput of goods. and achieve long-term business benefits.

In today’s hydraulic marketplace, original The greatest culprit in reducing throughequipment manufacturers (OEMs), end users, put is waste, which can translate to hydrauand all stakeholders involved need forward- lic machine downtime, lost time waiting for thinking suppliers to help them reach their materials, out-of-stock supplies, operator goals. But what does that look like? In simpli- errors, and poorly designed processes. fied terms, the goal is to increase productivSpecific to the fluid power industry, this ity, reduce costs, deliver innovations, improve model supports an advanced delivery program quality, and respond faster to customer needs. because of its unique design, which decreases These objectives are key components of a the need for product variations in inventory, business accelerator model, which ultimately simplifies logistics (less SKUs to manage), and translates into tangible business benefits. delivers on quality, flexibility, and just as imporThe business accelerator model impacts tant, modularity. A business accelerator model everything from the selection of materials to reduces overall cost to bring finished products design process and manufacturing. Purchas- to market and reach the objective outcomes: ing and supply management traditionally • Incorporate “base-level” design focused on price. However, these managers • Deliver product coverage for all application are starting to take heed of a bigger value conditions proposition and a more holistic view of their • Reduce overall number of SKUs materials purchasing and supplier selection • Decrease the number of vendors criteria. The model we are depicting fills the • Increase throughput via lean manufacturing gap that traditional suppliers have yet to • Provide supply chain advantages and savings offer—rethinking profitability and how to • Offer “shoulder-to-shoulder” design and achieve it. It has been developed to bring an testing over-arching, deeper understanding of the Suppliers today need to support their value a supplier can bring to impact the entire hydraulic equipment customers to increase supply chain and has “revenue-enhancing” their market share and generate additional effects on its customers’ businesses. Creating business value. Our business acceleration a collaborative environment creates more model does just that by improving our customagility, adaptability, and alignment, which is ers’ product development cycles and reducing really only possible when partners promote design, development, and delivery costs while knowledge flow between the highest areas of bringing greater value to the end product, impact within the supply chain. This atten- attracting prospects and increasing sales.

PUBLISHER INNOVATIVE DESIGNS & PUBLISHING, INC. 3245 Freemansburg Avenue, Palmer, PA 18045-7118 Tel: 800-730-5904 or 610-923-0380 Fax: 610-923-0390 | Email: AskUs@ifps.org www.FluidPowerJournal.com Founders: Paul and Lisa Prass Associate Publisher: Marc Mitchell Editor: Kristine Coblitz Technical Editor: Dan Helgerson, CFPAI/AJPP, CFPS, CFPECS, CFPSD, CFPMT, CFPCC - CFPSOS LLC Account Executive: Bob McKinney Art Director: Quynh Vo Director of Creative Services: Erica Montes Accounting: Donna Bachman, Debbie Clune Digital Strategy Manager: Jeff Maile Publishing Assistant: Sharron Sandmaier Circulation Manager: Andrea Karges INTERNATIONAL FLUID POWER SOCIETY 1930 East Marlton Pike, Suite A-2, Cherry Hill, NJ 08003-2141 Tel: 856-489-8983 | Fax: 856-424-9248 Email: AskUs@ifps.org | Web: www.ifps.org 2014 BOARD OF DIRECTORS President & Chairperson Tom Blansett, CFPAI, CFPS, CFPIHT, CFPCC - Behco-MRM, Inc. Immediate Past President Mark Perry, CFPHS - Fitzsimmons Hydraulics First Vice President Marti Wendel, CFPE, CFPS, CFPCC, Curtiss-Wright Sprague Products Vice President Education D. Dean Houdeshell, PE, CFPAI/AJPP, CFPE, CFPS, CFPIHT, CFPMHT, CFPMHM - Danfoss Treasurer Dan Helgerson, CFPAI/AJPP, CFPS, CFPECS, CFPSD, CFPMT, CFPCC - CFPSOS LLC Vice President Membership & Chapter Support Richard Bullers, CFPPS - SMC Corp. of America Vice President Certification Rance Herren, CFPSD, CFPECS, CFPMT, CFPAI, National Oilwell Varco Vice President Marketing & Public Relations Justin Sergeant, CFPS, CFPMHM, Seven Stars Industries Vice President Educational Foundation Jean Knowles, CFPE, CFPS, Applied Fluid Power DIRECTORS-AT-LARGE Alan Niesen, CFPS, CFPIHM, CFPMHM, HFI Fluid Power Products Kenneth Dulinski, CFPAI/AJPP, CFPECS, CFPHS, CFPMIH, CFPMMH Macomb Community College John Juhasz, CFPECS, CFPS, Kraft Fluid Systems, Inc. Timothy White, CFPAI/AJPP, CFPS, CFPECS, CFPMIH, CFPMMH, CFPMIP, CFPMT, CFPMM, The Boeing Company Frank Fetty, CFPMHM, JH Fletcher & Company Jeff Kenney, CFPIHM, CFPMHM, CFPMHT, Coastal Hydraulics, Inc. Scott Gower, CFPS, Gulf Controls Co., Inc. Scott Nagro, CFPS, HydraForce, Inc. Bill Jordan, CFPAI/AJPP, CFPMHM, CFPMHT, Altec Industries, Inc. Jose Garcia, CFPHS, Purdue University Rocky Phoenix, CFPMHM, Open Loop Energy, Inc. HONORARY DIRECTORS Robert Firth John Groot Raymond Hanley, CFPE/AI-Emeritus Robert Sheaf, CFPAI/AJPP, CFPE, CFPS, CFPECS, CFPMT, CFPMIP, CFPMMH, CFPMIH, CFPMM IFPS STAFF Executive Director: Donna Pollander, ACA Communications Manager: Adele Kayser Assistant Director: Jeana Hoffman Membership Coordinator: Sue Dyson Certification Coordinator: Susan Apostle Bookkeeper: Diane McMahon Administrative Assistant: Beth Borodziuk Fluid Power Journal (ISSN# 1073-7898) is the official publication of the International Fluid Power Society published bi-monthly with four supplemental issues, including a Systems Integrator Directory, OffHighway Suppliers Directory, Tech Directory, and Manufacturers Directory,

by Innovative Designs & Publishing, Inc., 3245 Freemansburg Avenue, Palmer, PA 18045-7118. All Rights Reserved. Reproduction in whole or in part of any material in this publication is acceptable with credit. Publishers assume no liability for any information published. We reserve the right to accept or reject all advertising material and will not guarantee the return or

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October 13-16, 2014 Nashville, Tennessee

M

FLUID POWER INNOVATION & RESEARCH CONFERENCE 2014

anufacturers, OEMs, researchers, and media from around the nation will convene at Vanderbilt University in Nashville, Tenn., from October 13-16, 2014 for the Fluid Power Innovation and Research Conference 2014 (FPIRC14), an extended series of educational events hosted by the Center for Compact and Efficient Fluid Power (CCEFP). The event will feature collaborative technical breakout sessions, networking opportunities, tours of local research laboratories, and panel discussions on the technologies and workforce skills transforming the fluid power industry.

Attendees at FPIRC14 will learn the latest in creative solutions to overcome hydraulic and pneumatic technical challenges. In addition to presentations on all the research and education activities of the CCEFP (which the NFPA Foundation now helps to support through its Pascal Society), there are some great opportunities for individuals and companies to connect with the talented students who are working on fluid power in the CCEFP. The technical poster presentations on the night of October 14 are an ideal general venue for this, but so are more targeted opportunities like the corporate kiosks and the corporate/ student speed meetings. Human resource professionals will find those activities worthwhile, especially those looking to add Bachelors, Masters, or PhD engineers to their workforce.

Another rare opportunity will be the tour of Oak Ridge National Laboratory (ORNL) on October 16. ORNL is home to the U.S. Department

of Energy (DOE)’s new manufacturing demonstration facility on additive manufacturing, and they are actively looking for industry partners to engage in some short-term projects to explore the applicability of these techniques to a variety of manufactured products, including fluid power components. Leading the tour is Dr. Lonnie Love of ORNL, who has been a vocal champion for fluid power in this regard and with regard to the NFPA’s efforts to expand fluid power’s footprint within the DOE. NFPA participated in the study prepared by Dr. Love for the U.S. DOE and is using it to help frame new technology development initiatives for the industry.

FPIRC14 PARTICIPANTS: • Industry practitioners and leaders • Government representatives • Academic fluid power researchers • Students from around the world RECOMMENDED ATTENDEES: • Fluid power engineers • Fluid power technical leaders • Human resource professionals • CTOs • Marketing personnel EVENT HIGHLIGHTS: • Premier fluid power technical conference • High-caliber panel on public-private partnerships in innovation, instruction, learning, and research to marketplace • One-on-one meetings with fluid power experienced students

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PANELISTS: • Nicholas Zeppos, Chancellor, Vanderbilt University • Philippe Fauchet, Dean of Engineering, Vanderbilt University • Mark Johnson, Director of Advanced Manufacturing Office, U.S. DOE • Thom Mason, Director, Oak Ridge National Laboratory • Ken Gray, Global Product Manager, Large Hydraulic Excavators, Caterpillar Inc.

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CIRCLE 127

TECH DIRECTORY 2014

5

Is Your Air Compressor Control

Smarter

Than a Four Year Old?

O

By Ron Marshall for the Compressed Air Challenge

ne of the biggest problems in compressed air systems with rotary screw compressors is inefficient compressor control. Hundreds of thousands of air compressors throughout the world are running at this very moment when they could be turned off,

saving their owners significant electrical costs.

These machines do so because their controls are not “smart” enough or haven’t been enabled to turn the motor off when not in use. A four-yearold child can be trained to save energy by turning out the lights, but some compressor controls are just too “dumb” to learn to turn off automatically.

Rotary screw compressors often operate in systems where the whole capacity of one or more compressors is not required all the time.

When an air compressor is partly loaded, some method of control is required to unload the compressor. If the compressor was not controlled, it would keep adding its full capacity into the system and the pressure would keep rising due to the excess air production until something blew.

Various methods of controlling part loading exist, but the most common is load/unload control (also known as “online/offline”) where the compressor loads and unloads to the proportion of the present loading condition. If the compressor is half loaded, it will be in the loaded condition, making its full output capacity 50% of the time while the other 50% will be in an unloaded condition. If lighter loaded, say 30%, the unloaded portion would be 70% – simple math. The problem is that while running unloaded, the air compressor consumes about 35% of its full-load power, sometimes more, while producing zero air. Therefore, systems that are lightly loaded, such as units located in equipment repair shops and body shops, can spend many wasteful hours running unnecessarily.

Basic air compressor controls simply provide pressure control where the compressor will load at a certain pressure and unload at a slightly

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higher pressure, usually 10 psi higher. The most common and simplest of these controls always keep the compressor running, even when the unit has been running unloaded for hours.

Slightly smarter and more advanced controls can detect if the compressor has been running unloaded for a significant period of time and will shut the motor off after a set length number of typically around 10 or 15 minutes. This can save power in multiple compressor systems where all the compressors are not needed all the time due to varying levels of air demand, but in systems with only one compressor running, this rarely allows the remaining compressor to run partly loaded in an efficient manner.

Typically there is not enough storage capacity in a compressed air system, and/or the pressure band of the load/unload settings are too narrow to allow the compressor to remain unloaded for times that are anywhere near the 10 to 15 minutes of a standard compressor unload timer. For example, a 25-hp compressor with a storage receiver sized at about two gallons per full load CFM output of the air compressor (200 gallons) running at 25% loading with a 10-psi pressure band would only remain unloaded about 45 seconds of its approximately one-minute cycle.

If it were set to turn off during the unload time, it would start over 60 times per hour! Electric motors should not exceed the maximum allowable starts per hour or damage will occur, hence the need for unload timers. In the case of a 25-hp, three-phase compressor motor, the maximum number of starts per hour is about six.

Some manufacturers are starting to offer “smart” compressor controls that are designed to recognize the periods of time when a compressor motor can safely turn off. If you have one of these compressors or can replace your aging compressor with a new one with “smarts,” you can use this to your advantage to save energy. The controls work by counting the number of starts per hour or monitoring the characteristic load/unload cycle frequency. If conditions exist where the example compressor discussed was only running at a frequency of six cycles per hour, then the compressor would immediately turn off when it unloaded, saving power for the 75% of the time it remained unloaded. If exceeding the maximum, it would turn off the compressor for only some of the unload cycles, not exceeding the maximum. But to get to this condition, there has to be some intervention from the owner or operator of the equipment to reduce the number of starts. In our example, the reduction needs to be by a factor of ten.

This reduction can be done by adding storage and widening the pressure band. If, for example, the same 25-hp compressor was installed with 1,000 gallons of storage capacity and set to run with a 20-psi pressure band, the same unit would only start six times per hour at 25% duty. This

is the time it takes to reach the lowest unloaded power, often stretching to two minutes.

strategy would reduce the compressor run time by 75% and completely eliminate the wasteful unloaded run time. The savings gained from this would result in an energy reduction of about 23%, which would save about $5,000 per year for a compressor of this size running full time at a power cost of 10 cents per kWh. The maintenance-related savings will be significant, as well, due to the reduction in run hours. The savings might be greater than calculated here if the compressor has a very long blow down time, which

U

tilizing a compressor with smart control and adding a smart strategy of your own can save you significant power costs and help your compressor last longer. To learn more about condensate drainage, consider taking part in Compressed Air Challenge’s next Fundamentals of Compressed Air Systems webinar. Go to www.compressedairchallenge.org to see how.

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TECH DIRECTORY 2014

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‰ ECONOMIC REPORT YEAR-TO-DATE GROWTH IN MANUFACTURING EXPORTS FOR THE TOP 10 U.S.-MANUFACTURED GOODS EXPORT MARKETS

11.6%

9.4%

Global Manufacturing Update

8.5% 7.6% 5.5%

5.0%

BY CHAD MOUTRAY, CHIEF ECONOMIST, NATIONAL ASSOCIATION OF MANUFACTURERS (NAM)

August 8, 2014 – The International Monetary Fund (IMF) predicts that world output will grow 3.4% in 2014, down from 3.7% in its April forecast. Much of the downward movement stems from weaker-than-expected data from the first quarter. In the United States, for instance, real GDP declined by a disappointing 2.1%, and even with a rebound in the second quarter, the economy expanded by just 0.9% in the first half. Fortunately, manufacturers are mostly upbeat about the second half, and the IMF predicts 1.7% and 3.0% growth in the United States for 2014 and 2015, respectively.

Europe is anticipated to grow 1.1% this year,

0.3%

-0.7% Canada

Mexico

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Japan

Germany

Brazil

United Kingdom

Hong Kong Netherlands

2014 YTD (January to June, relative to the same time period in 2013) and the Chinese economy should increase by 7.4%. While the emerging markets as a whole have started to see signs of improvement, notable weaknesses still exist in Brazil, Russia, and South Africa, to name just a few. Geopolitical risks abound, of course, with crises around the world also negatively impacting activity.

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China

-0.6%

0.0%

The good news is that global manufacturing activity continues to expand modestly, with the pace little changed in July from June. New orders, production, and employment growth slipped a little for the month, but exports picked up. In July, eight of the top 10 markets for U.S.manufactured goods had expanding econo-

South Korea

mies, with Brazil and South Korea contracting once again. Among the expanding nations, Canada and China saw accelerating levels of manufacturing demand and production in July, with relatively decent growth seen in both the Netherlands and the United Kingdom. At the same time, manufacturers in the United States have continued to rebound from softness earlier in the year. The Institute for Supply Management’s Manufacturing Purchasing Managers’ Index (PMI) increased to its highest level since November on strong output and sales growth.

The Chinese economy has begun to stabilize, with manufacturers in China expanding for the second straight month. New orders, exports, and production growth all strengthened in July, and we anticipate a pickup in industrial production and fixed-asset investment rates when they are released next week. China’s real GDP has increased slightly from 7.4% at the annual rate in the first quarter to 7.5% in the second quarter. Meanwhile, Eurozone manufacturers have now expanded for 13 straight months, but activity has decelerated since January. Confidence measures have weakened, year-over-year inflation remains very low, and the unemployment rate stayed elevated (even as it fell to

package that would add an estimated $1 trillion to the world economy, potentially setting up a last-ditch effort to revive the deal in September.

Responding to rising tensions in the Ukraine, the United States and the European Union (EU) imposed fresh sanctions on Russia in the financial, energy, and defense sectors.

With Congress now in recess for the month of August, manufacturers are engaging Senators and Representatives in their states and districts, and gearing up for action in the fall on a range of stalled trade measures—including reauthorization of the Export-Import Bank, Trade Promotion Authority, a miscellaneous tariff bill, and the Generalized System of Preferences. A House bill that would provide access to federal civil enforcement for trade secrets theft is fast gaining cosponsors, laying the groundwork for a Judiciary Committee markup and possible passage in September. The planned official visit of India’s new Prime Minister, Narendra Modi, to Washington at the end of next month will provide another opportunity to address outstanding trade and investment barriers in that important market.

The National Association of Manufacturers (NAM) represents small and large manufacturers in every industrial sector in all 50 states. For more information, visit www.nam.org.

11.5%). Still, the latest industrial production and retail sales have reflected a rebound.

In general, we have seen the U.S. trade deficit narrow over the past couple years as we have become less dependent on foreign sources of energy. In June, the trade deficit was at its smallest level since January as goods imports declined at a faster pace than goods exports increased.

Still, we continue to see relatively slow growth for U.S.-manufactured goods exports, which have increased 1.7% year-to-date. Ideally, we will see improvements moving into the second half, as the current pace represents a deceleration from last year’s 2.6% rate of growth.

The last month saw important progress on ongoing trade negotiations with Europe and 11 Pacific Rim nations, as well as environmental goods talks in the World Trade Organization (WTO). However, India and others successfully blocked agreement on a global trade facilitation

Excerpt reprinted with permission. For the full report, visit www.nam.org.

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CIRCLE 132

TECH DIRECTORY 2014

9

FLUID POWER CASE STUDY

HYDRAULIC OUTPUT TRIPLED, Manufacturing Headaches Eliminated

10

WWW.FLUIDPOWERJOURNAL.COM | WWW.IFPS.ORG

BY EUROTECH While everyone wants to stay on the road to continuous improvement, many are too busy fighting fires and can’t make the time to begin their improvement journey. One of the biggest headaches that so many manufacturers face is process improvement. A machine shop located in Clearwater, Fla., found a solution that put them ahead of the competition—less stress, fewer late work nights, fewer defective parts, etc.

“To stay competitive and keep work here in the United States, we were looking for new ideas and better technology. We needed to improve our output and processes, so we were looking for equipment that would hold extreme tolerances while reducing our load/unload time, cycle time, and scrap rates. The Eurotech machines did this and more. We can complete operations on one machine in one operation,” said Macky Mongold, one of the owners of Model Screw.

Model Screw was founded in 1948 in St. Louis, Mo., by David Feldman. One of Mr. Feldman’s hobbies was building model steam engines. He started the company to build “to-

scale” hex head bolts for sale to model builders, hence the name “Model Screw Products.”

The company took off and began making precision parts for several defense and commercial companies. In 1972, Marvin Feldman (David’s son) moved the company to Clearwater, Fla, where it has grown to a working team of over 125 people and a 42,000-sq. ft. facility.

Model Screw supplies parts mainly to the hydraulics industry, such as Sun Hydraulics, Parker Hydraulics, and Hydac, as well as to military and automotive companies, such as Chrysler, Caterpillar, John Deere, and Cummins. “For over 60 years, we have built long and strong business relationships with our customers by delivering to their high standards,” explained John Wilcox of Model Screw.

Model Screw uses the Eurotech machines for many different parts. From spools, sleeves, pistons, and valve bodies, all the parts are completed on one machine and in one operation. “We have reduced our cycle times by over 30%, and in some cases by 50%, plus we’ve

Hex body manufactured on the Eurotech. In the past, this part was made with three operations. It has been reduced to one operation and shaved a full minute off the cycle time, resulting in a 35% cycle-time savings.

Hydraulic part that Model Screw has been selling to a customer for almost 20 years.

The company has removed two secondary machining operations. Cycle time was cut by 73 seconds, resulting in 33% cycle-time savings.

Hydraulic part sold by Model Screw for over 10 years.

Secondary machining operations was removed, resulting in approximate machining cycletime savings of 31%.

reduced our operations and handling. We’ve created a single-step process (one and done!), and this has allowed for less inventory, less labor, less scheduling headaches at multiple machines, and less time/cost of quality checks,” said Wilcox.

Model Screw currently owns both Eurotech 11-axis and 13-axis machines—one dual turret and two triple turret. The B465SY2 is from Eurotech’s dual-turret Trofeo series. This model has a main and a (Clearshift) sub-spindle with Y-axis upper turret, Y-axis lower turret, and live tools on both turrets (2.75" bar capacity).

The B465T3Y3 is from Eurotech’s triple-turret Multipla series. This model boasts a main spindle and three Y-axis turrets, plus sub spindle, C-axis, live tools on all three turrets, and a 2.75" bar capacity.

Eurotech is a family-owned business that offers a network of local, full-serve distributorships with over 200 multi-axis service engineers in the field. Visit www. eurotechelite.com. For more information on Model Screw Products, visit www.modelscrewproducts.com.

John Wilcox and Macky Mongold of Model Screw Products in Clearwater, Fla., in front of one of their Eurotech 3-turret, 13-axis hydraulic machines

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AIR TEASER

New Problem This question varies a bit from the normal Air Teaser, however it still uses some of the same formulas that are used to determine a force to overcome motion.

You have a building 12' high, 8' wide, and 20' long that has a flat roof. The wind is hitting the side of the building straight on (12' x 20') with a 60-mph speed. How much would the building need to weigh to keep it from tipping over if it was only anchored on the left side to keep it from sliding? The building is uniformly loaded.

? Weight

TWO USEFUL EQUATIONS: HP = Pounds of Pull x Distance in Feet / Sec.

550 HP = FA x MPH3 150,000

60 MPH Wind

12

FA = Square feet of surface area

8

Anchor

PREVIOUS PROBLEM

Drawing by Jeff Parker

In designing a vehicle to go down the road at 60 mph, one must know the drawbar pull of the vehicle. This is a combination of drag coefficient, rolling resistance, grade of incline, and any mechanical inefficiency. To find this information without a wind tunnel, one might use a scale of some type and pull the vehicle with a long tow-rope. Using a pneumatic

cylinder with the blind end open to atmosphere and the rod end closed and fitted with a pressure gauge, we can make a nice scale that can be used to determine the horsepower. If the pneumatic cylinder has a bore of 3 inches, what would be the rod size required to have the pressure on the gauge be equal to the drag horsepower when traveling at 60 mph?

SOLUTION Equation to find HP: HP = pounds of full x (feet / second)

550 Let’s use 10 hp as an example.

The area of a 3" cylinder = 7.068 sq. in.

Cap end area – rod end area (EREA) = rod area.

7.068 – 6.25 = 0.818 sq. in. of rod area.

(5,280 feet in a mile / 60 seconds in a minute) = 88' / sec.

Solving: 10 x 550 / 88 = 62.5 pounds of pull. This means it takes 10 hp at 88’ / sec. with 62.5 # of pull.

Using F = PA: We will use 10 psi because that equals our 10 hp.

Force of 62.5 / 10 psi will need 6.25 sq. in. of rod end area (EREA).

Solve for diameter

A = D2 x 0.7854

Working backwards:

A / 0.7854 = D2

By Ernie Parker, AI, AJPP, AJPPCC, S, MT, MM, MIH, MIP, MMH, Fluid Power Instructor, Hennepin Technical College, EParker@Hennepintech.edu

√ of (0.818 / 0.7854) = 1.02" or a 1" rod. Now your pressure gauge will read both PSI and HP.

WINNER OF PREVIOUS PROBLEM

ANSWERED CORRECTLY

Kevin Peyton

George Fling, CFPS Southwestern Controls, Inc. Dallas, TX

Karl Kersker, CFPS; CFPE ATK Launch Systems Pleasant View, UT

Ehren Polheber, CFPS Scot Forge Company Salem, WI

Timothy Preston, CFPS Berendsen Fluid Power Ltd Smyrna, GA Jim Lane Bosch Rexroth

Reinforce your industry expertise with a Pneumatic Mechanic, Technician, or Specialist certification. Apply online at www.ifps.org.

The teaser is posted on the IFPS website (www.ifps.org) and also printed in the Fluid Power Journal. Submit your information via the website, or fax it to 856-424-9248 attn: Donna Pollander. Those who submit the correct answer before the deadline will have their names printed in the Society Page newsletter and in Fluid Power Journal. The winners will also be entered into a drawing for a special gift.

12

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Eaton “Educates the Educators” at its 2014 Instructor Symposium Every year, Eaton aims to “teach the teachers” the latest information

covering a variety of fluid power components and technologies. Students studying hydraulics in vocational settings or technical colleges and universities learn the most up-to-date curriculum in classes, hands-on labs, and demonstrations.

Safety was a key message of this year’s symposium, which was held July 29-31 at Eaton’s training center in Maumee, Ohio. As new classes of fluid power specialists hit the workforce, it’s critical they understand how to properly use fluid power components to meet the engineering specifications of heavy, complex equipment.

Tom Blansett, CFPAI, CFPS, CFPIHT, CFPCC, Eaton Hydraulics Group North American Training Manager and 2014 IFPS president, said industry developments to facilitate hydraulic systems that produce higher pressures underscore the importance of keeping all professionals up to speed on the latest developments.

The 2014 Eaton Instructor Symposium covered topics including aeration and cavitation, Controller Area Network (CAN) basics, hose technology and assembly techniques, thread and port ID, advanced pump controls, sensor technology, systemic contamination control, logical troubleshooting with bar trim and simulators, proportional valve control technology, and Eaton’s Life Sense® hose health monitoring system.

“As products become smaller and capable of withstanding higher operating pressures, along with more complex integration with electronics and software, it is important for industry trainers to stay up to date on the latTo learn more, visit www.eaton.com/hydraulics.

Left: A fluid power educator measures fittings at Eaton’s annual Instructor Symposium.

Right: An instructor demonstrates the Eaton Pro-FX™ and its motion control capabilities in a workshop at the Instructor Symposium.

est technological developments across the fluid power industry,” said Blansett. “Eaton admires the dedication and energy of these educators, and sessions like this Instructor Symposium help teachers dig deeper into new developments while learning to apply traditional products and technologies in new ways.”

Eaton’s training programs date back to 1945, and its Hydraulics Group Training Services staff has a total of 140 years of experience in hydraulics and education. With an expansive history of fluid power tutelage, Eaton has established the Instructor Symposium and Eaton’s company training programs as industry standards in everything from mobile hydraulics to electro-hydraulics.

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PROFILE: FLUID POWER SUCCESS STORY

INTERNSH

IPS AT

MAGNETE

K Provide Ex perience, Opportuni ty

By Matt Ger geni, Magne

tek, Inc. Kevin Luty at his internship

I

n the Spring of 2012, when software engineering student Kevin Luty began his search for an internship the summer after his junior year, his ultimate goal was to gain experience that would not only look good on his resume, but also would help him land a job after graduation.

Little did he know that the time he would spend developing and testing software for material-handling products while gaining real-world work experience at Magnetek, Inc. that summer would lead to bigger things.

With nearly 13% of U.S. workers still considered to be unemployed or underemployed*, many of today’s college students are actively

Magnetostrictive noncontact technology; resolution to 1 micron Supports Star, Line or DLR topology

Three standard M12 connectors — 1 power, 2 communications

Wide input power supply range (7–30V) may reduce external power supply requirements Set IP address from network PC or the last octet via the RapidRecall DIP switches

What to do

when analog won’t do.

RapidRecall™ module stores all user configuration settings

Introducing the ReadyLink™ Network LDT

Five status LEDs monitor LDT and network status Status bits warn of position/ velocity outside of programmed range

Built-in web pages for easy configuration

Automation solutions require accurate feedback of continuous position regardless of the application environment. Analog position sensing devices can have shortcomings in automation applications, including limited features, resolution and cable lengths. That’s why the ReadyLink Linear Displacement Transducer is a far better solution.

Feature for feature, it lets you do—and measure—so much more.

Learn more about this smart device technology at ametekfactoryautomation.com. © 2014 by AMETEK. All rights reserved.

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seeking opportunities to better prepare themselves as they transition into the workforce.

The employment challenges facing the class of 2014 represent a unique opportunity for companies that are willing to invest both time and resources into the future of their industry. In fact, companies today have an opportunity to offer students a meaningful work experience in

WWW.FLUIDPOWERJOURNAL.COM | WWW.IFPS.ORG

return for access to a readily available source of knowledge in terms of new technologies and the most recent schools of thought.

Even if your goal is simply to recruit new job candidates, think of college internship programs as a three-month-long interview where at the end of the process you’ll have great insight into the interviewees’/interns’ level of knowledge, work ethic, and abilities. All in all, internship programs can provide companies, especially small to mid-sized businesses, with a powerful tool that can be used to help find and retain quality employees.

For more than two decades, Wisconsinbased Magnetek, Inc. has provided engineering internship opportunities for college students in the Wisconsin region and beyond. Magnetek manufactures and markets digital power and motion control systems for material handling, fluid power, people-moving, and mining applications. The company is a leader in wireless control products for mobile hydraulic applications. Since the program’s inception, the company’s approach to creating relevant internship opportunities has focused on developing realworld work opportunities that provide students with job-specific work experience in the development, product management, buyer-planner, and production engineering fields.

“Our program offers only as many internships each year as are deemed vital by our business leaders,” said Caitie Bowers, a member of Magnetek’s human resource team who works directly with the company’s internship program. “We are focused on providing work experiences that put the students into a realworld work environment and are designed to benefit both the student and our organization. It’s a win-win situation for everyone.”

According to Magnetek’s internship program leaders, the first steps in developing an effective internship program are to evaluate your business needs and resources, devote adequate time and resources during the planning process, and to think long range.

“Our internship program exposes our company and our products to students and poten-

tial employees who may not have heard of us before,” said Guy Moore, a development director at Magnetek. “The students bring a lot of enthusiasm, new ideas, and concepts they have learned through their coursework. During our internship process, they are partnered with senior engineers and given a chance to get involved in project planning and testing that gives them first-hand experience and insight into how the product development process works in a professional environment. In fact, in some cases, our interns continue working part time for us even after the initial internship has been completed.”

In order to provide a high-quality internship experience, it’s important that companies, from the top down, embrace the internship concept and invest adequate time and resources to guarantee that the program benefits both the student and the company. It’s also important to develop a well-crafted implementation plan so that interns who will be trusted with varying degrees of responsibility have a clear understanding of the program’s expectations and receive adequate training from day one.

“The key to having a mutually successful internship program is having employees and business leaders who are ready and willing to mentor the interns and create a challenging internship experience,” said Bowers. “When managed successfully, internship programs offer a way to access willing workers who can assist in getting projects completed, provide potential employees with valid work experience, and gain new insight into the most upto-date programs and processes being taught at the university level.”

For Kevin Luty, the opportunity that Magnetek’s internship program delivered— including the chance to develop software that he could immediately see adding value to actual products in the market—provided more than just experience he could add to his LinkedIn profile. It gave him the opportunity to achieve his ultimate goal upon graduation: transforming his internship experience into a full-time job at Magnetek.

E FOR MOR

N

TIO INFORMA

r eni is senio Matt Gerg ons ti a ic n g/commu in et rk a m ek. He at Magnet specialist 2-373ched at 26 can be rea geni@ atthew.ger 3151 or m more rn a .com. To le magnetek it is v , ek gnet about Ma . m o .c ek gnet www.ma

*Fox Business: http://www.foxbusiness.com/personal-finance/2014/05/07/can-midcareer-internship-boost-your-career/ CIRCLE 137

TECH DIRECTORY 2014

TECH DIRECTORY 2014

ADACONN®

Custom Reducing Flange Adapter Solutions SAE J518 flange to JIC, ORS, NPTF, and SAE J1926 male ends available in multiple size reductions. © 2014 ADACONN®

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(800) 597-6577 www.amthydraulics.com hydraulic, pneumatic, electrical training

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TECH DIRECTORY 2014

Your Source for Servo & Proportional Valves

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� Provide first class repairs in state-of-the-art lab � All units 100% tested

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“Control Reliable” Machine Guarding Safety Devices & Controls for Pneumatic and Hydraulic Control Systems for OSHA & ANSI Compliance

www.pinnaclesystems.com (800) 569-7697

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TECH DIRECTORY 2014

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832-331-0021 • sales@weh.us • www.weh.us

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TECH DIRECTORY 2014

Get Social With Us!

TECH DIRECTORY 2014

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BY PSI REPAIR SERVICES

REPAIRINGin Seismic HYDRAULIC SERVO VALVES Vibrator Trucks

S

eismic vibrator trucks (aka “thumper trucks”) send shockwaves deep into the earth’s subsurface to locate untapped hydrocarbon reserves for the oil and gas industry. These shock/soundwaves reflect back to the surface, where they are picked up and recorded by geophones. This seismic data is later imaged with advanced software (think: ultrasound) and analyzed by geologists who advise oil companies on where to drill for oil reserves (Fig. 1).

Not surprisingly, high-quality seismic data is mission critical. Geophysical surveys can cost $50,000 or more per square mile depending on the territory, and multi-million dollar projects—sometimes billion-dollar projects—are ultimately on the line. In short, there’s no tolerance or margin for error in this industry.

Thumper trucks are intricate machines, however, powered by complex hydraulic and mechanical systems. To generate the massive force necessary for a controlled and effective sound blast (for perspective, dynamite used to be the preferred method for this), all equipment must be highly precise and high performing (Fig. 2).

When the base plate of the vibrating truck rapidly “thumps” the ground, the vibration puts acute stress on the mechanics driving the action. Hydraulic servo valves are a key example of this. By porting fluid and directing the hydraulic actuator to vibrate the base plate, servo valves are especially important components that are susceptible to wear and malfunction.

High-intensity vibration exposes these high-performance valves, which are usually complex three-stage and four-way valves, to a variety of problems that can corrupt other parts and lead to failure and downtime.

Although these issues are difficult to diagnose in the field, servo valve failure is most often caused by the following: • Contamination: servo valves in vibrator trucks are exceptionally precise

Fig. 1: Source: http://lingo.cast.uark.edu/LINGOPUBLIC/natgas/search/index.htm

assemblies, and the smallest particles can cause them to fail.

• Internal part failure, especially »» torque motor failures »» spools wearing out »» AFSAs (a directional needle inside the servo valve) developing flat spots Unfortunately, pinpointing the faulty servo valve component is only half the battle.

Regardless of whether or not the defective or broken part is identified, most geophysical exploration companies rely on the component’s OEM to restore equipment to working order. This dependence on OEMs is a costly and inefficient arrangement because it typically only provides customers with one option: replace your out-of-warranty defective parts with brandnew (expensive) parts.

Fig. 2: Source: http://hydraulicspneumatics.com/other-components/hydraulics-delivers-good-vibrations PSI’s servo valve lab operations are set in a temperaturecontrolled, clean room environment. When a defective valve is shipped to the PSI facility and the staff determines the extent of the damage, the following repair steps are executed: 1. Test servo valves on run-in test stands. »» Check performance to OEM specifications. »» Determine repair requirements.

2. Analyze fluids running through the customer’s process. »» Recommend fluid improvements. »» Suggest maintenance requirements.

3. Disassemble valve.

4. Clean all parts ultrasonically in a heated vapor degreaser system.

5. Replace all broken, worn, and missing parts.

6. Reassemble the valves using new Viton seals.

7. Test valves on a dedicated test stand capable of low and high flow testing.

When the PSI repair process is complete, the remanufactured, like-new condition servo valve will always meet the same industry specifications for performance as new valves, and it will often exceed the expected lifetime of the original valve.

FOR MORE INFORMATION, CALL 800-325-4774 OR VISIT WWW.PSI-REPAIR.COM/CONTACT-US.

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IFPS NEWS

CERTIFICATION DESIGNATIONS AVAILABLE

CFPAI

CFPAJPP

CFPAJPPCC

CFPE

CFPS

CFPHS

Certified Fluid Power Accredited Instructor

Certified Fluid Power Authorized Job Performance Proctor

Certified Fluid Power Authorized Job Performance Proctor Connector & Conductor

Certified Fluid Power Engineer

Certified Fluid Power Specialist (Must Obtain CFPHS, CFPPS)

Certified Fluid Power Hydraulic Specialist

CFPPS

CFPPM

CFPMEC

CFPIEC

CFPMT

CFPIHT

Certified Fluid Power Pneumatic Specialist

Certified Fluid Power Pneumatic Mechanic

(in development) Mobile Electronic Controls

(in development) Industrial Electronic Controls

Certified Fluid Power Master Technician (Must Obtain CFPIHT, CFPMHT, & CFPPT)

Certified Fluid Power Industrial Hydraulic Technician

CFPMHT

CFPPT

CFPMM

CFPIHM

CFPMHM

Certified Fluid Power Mobile Hydraulic Technician

Certified Fluid Power Pneumatic Technician

Certified Fluid Power Master Mechanic (Must Obtain CFPIHM, CFPMHM, & CFPPM)

Certified Fluid Power Industrial Hydraulic Mechanic

Certified Fluid Power Mobile Hydraulic Mechanic

CFPMIH

CFPMMH

CFPMIP

CFPCC

CFPSD

Certified Fluid Power Master of Industrial Hydraulics (Must Obtain CFPIHM, CFPIHT, & CFPCC)

Certified Fluid Power Master of Mobile Hydraulics (Must Obtain CFPMHM, CFPMHT, & CFPCC)

Certified Fluid Power Master of Industrial Pneumatics (Must Obtain CFPPM, CFPPT, & CFPCC)

Certified Fluid Power Connector & Conductor

Fluid Power System Designer

IFPS Web Seminars VISIT WWW.IFPS.ORG TO REGISTER OR CALL 800-308-6005.

IFPS MEMBERS: FREE • NON-MEMBERS: $40.00 DECEMBER 11, 2014

APRIL 16, 2015

“Mobile Equipment Reservoir Baffle Innovation” 12:00 p.m. – 1:00 p.m. Eastern Presented by: Robert Post, WastAway As presented at IFPE 2014 - A practical solution for fluid control inside small mobile equipment reservoirs, which reduces damage, spillage, and equipment failures.

“Proper Sizing of Conductors When Using Single Rod Cylinders” 12:00 p.m. – 1:00 p.m. Eastern Presented by: Ernie Parker, CFPAI, Hennepin Technical College This presentation will cover proper line sizing of plumbing when using single rod cylinders and also explore pressure intensification due to some type of meter-out circuits. There are various standards for velocities concerning plumbing, and yet if the math is truly done properly, most of the hydraulic plumbing and cylinder ports are not sized properly. This webinar will discuss these concepts using very basic math to make participants aware of these problems for future sizing of components and plumbing.

FEBRUARY 12, 2015 “Filter Sizing: Pressure vs. Return Flow Filters” 12:00 p.m. – 1:00 p.m. Eastern Presented by: Bill Hotchkiss, CFPAI, SunSource This presentation will cover the following topics: • Filter sizing for pressure lines, return lines, and for off-line recirculation • Benefits of pressure line vs. return line vs. off-line filtration • Micron selection for use with pressure line vs. return line vs. off-line filtration

View archived seminars at www.ifps.org

Visit www.ifps.org for more information.

CONGRATULATIONS to the following new Accredited Instructors (CFPAIs) and Job Performance Proctors (AJPPs): • Joey Clemmons CFPAI/AJPP, CFPS, CFPIHM • George Heid, Controlled Fluids, Inc. – CFPAJPP/CC, CFPMIH, CFPHS • William Hotchkiss, Sunsource CFPAI/AJPP, CFPS • Robert Koehler, Eaton CFPAI/AJPPCC, CFPCC • Jyotsna Phadke, Eaton CFPAI, CFPHS • Denis Poirer, Jr., Eaton CFPAI/AJPP/CC, CFPCC • Chad Rolfe, Open Loop Energy Inc. – CFPAI/CFPAJPP/CC, CFPS, CFPSD • Joseph Snider, Serco Inc. CFPAJPP, CFPMHM Next training class for Accredited Instructor certification will be in April 2015. To learn more, visit www.ifps. org or call 800-308-6005.

TECH DIRECTORY 2014

27

IFPS Calendar VISIT WWW.IFPS.ORG FOR REGISTRATION INFORMATION.

MEETINGS AND CONFERENCES

CERTIFICATION REVIEW TRAINING

Connector & Conductor (CC) Review w/ Job Performance Test

Hydraulic Specialist (HS) Certification Review

IFPS 2015 Spring Meeting February 24-28, 2015 Houston, TX

Job Performance Online Review – CFC Industrial Training, Inc. offers online JP Reviews, which include stations 1-6 of the IFPS Mechanic and Technician Job Performance Tests. Members may e-mail askus@ifps.org for a 5% coupon code off the list price for the entire IFPS Job Performance Review (test not included).

Review and testing offered through Pirtek USA Rockledge, FL Review: November 5, 2014 Job Performance Test: November 6, 2014 (9:00 a.m.) / written test: November 6, 2014 (1:00 p.m.)

Distance Learning Review Sessions offered through CFC Industrial Training. October 2014 classes available.

Review and testing offered through NTT Training Centennial, CO Review: November 11-12, 2014 Job Performance and written tests: November 13, 2014

Distance Learning Review Sessions offered through CFC-Solar, Inc. October 2014 classes available.

IFPS 2015 Annual Meeting September 22-26, 2015 location tba IFPS 2016 Spring Meeting February 23-27, 2016 Location tba IFPS 2016 Annual Meeting September 27 - October 1, 2016 Location tba

Live Distance Learning Job Performance Station Reviews.

E-mail register@cfc-solar.com for information.

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Pneumatic Specialist (PS) Certification Review

CIRCLE 139

IFPS NEWS

IFPS NEWLY CERTIFIED PROFESSIONALS Cody Allen, MHM, Altec Industries, Inc.

Nicholas LeBoutillier, HS, Sun Hydraulics

Norman Simon, MHM, Altec Industries, Inc.

Henry Story, IHM, Hydrotech, Inc.

Mark Turner, CC, Pirtek - Inland Valley

Dan Brock, MHM, Altec Industries, Inc.

Raymond Mak, HS, Sun Hydraulics

Chris Smith, CC, Pirtek - Woodinville

Eric Suszka, HS, Sun Hydraulics

Peter Warne, MHM, Baltimore Gas & Electric Co.

Frank Castoral, HS, Sun Hydraulics

Gideon Martin, MHM, Altec Industries, Inc.

Santos Correa, MHM, El Paso Electric Co. Abel Dressel, CC, Pirtek - Kent Bradley Dunham, HS, Sun Hydraulics Zachary DuPerier, HS, Sun Hydraulics David Entwistle, CC, Pirtek - Rockville Anthony Farino, MHM, Altec Industries, Inc. Jorge Garay, MHT, El Paso Electric Co. McNeil Garton, MHM, Altec Industries, Inc.

Kyle Moyers, MHM, Altec Industries, Inc. Benjamin Opp, CC, Pirtek Chicagoland Jacob Paulsen, MHT, El Paso Electric Co. Terrinse Perez, CC, Pirtek Rockville Katherine Piepszny, S, PS, The Walt Disney Company

Robert Garton, MHM, Altec Industries, Inc.

Michael Prestas, Jr., MHM, Altec Industries, Inc.

Michael Grant, CC, Pirtek - Kent

Kevin Price, CC, Pirtek - Rockville

Craig Griffiths, HS, Applied Engineering

Bishwajit Ranjan, S, PS, Wyman Gordon Houston

William Harper, CC, Pirtek USA

Timothy Riley, HS, Ronald Holloway, MHM, Altec Industries, Inc. Ryan Horner, CC, Pirtek - Rockville Donald Kendrick, MHM, Altec Industries, Inc.

David Salcedo, CC, Pirtek Commerce South Evan Schrantz, MHM, Altec Industries, Inc.

Kerry Kissinger, CC, Pirtek USA CIRCLE 140

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IFPS NEWS

I

IFPS Certification Testing Locations

ndividuals wishing to take any IFPS written certification tests are able to select from convenient locations across the United States and Canada. The IFPS is able to offer these locations through its affiliation with The Consortium of College Testing Centers (CCTC) provided by National College Testing Association (NCTA).

To register for an IFPS written certification test: 1. Fill out an IFPS certification test application including your desired location by visiting www.ifps.org.

2. Submit your application with payment to IFPS headquarters.

3. Upon receipt of your application, you will be e-mailed instructions.

TESTING DATES FOR ANY LOCATIONS LISTED BELOW ARE AS FOLLOWS: OCTOBER 2014 Tuesday, 10/7 Thursday, 10/16

NOVEMBER 2014 Tuesday, 11/4 Thursday, 11/20

DECEMBER 2014 Tuesday, 12/2 Thursday, 12/18

JANUARY 2015 Tuesday, 1/6 Thursday, 1/15

FEBRUARY 2015 Tuesday, 2/3 Thursday, 2/19

MARCH 2015 Tuesday, 3/3 Thursday, 3/19

APRIL 2015 Tuesday, 4/7 Thursday, 4/16

Questions? Please call IFPS at 800-308-6005.

ALASKA Anchorage, AK Fairbanks, AK

South San Francisco, CA Yucaipa, CA

ALABAMA Auburn University, AL Birmingham, AL Decatur, AL Huntsville, AL Jacksonville, AL Mobile, AL Montgomery, AL Normal, AL Tuscaloossa, AL

COLORADO Aurora, CO Boulder, CO Centennial, CO Colorado Springs, CO Denver, CO Durango, CO Ft. Collins, CO Greeley, CO Lakewood, CO Littleton, CO Pueblo, CO

ARKANSAS Bentonville, AR Hot Springs, AR Little Rock, AR

ARIZONA Flagstaff, AZ Glendale, AZ Mesa, AZ Phoenix, AZ Prescott, AZ Scottsdale, AZ Sierra Vista, AZ Tempe, AZ Thatcher, AZ Tucson, AZ Yuma, AZ CALIFORNIA Aptos, CA Arcata, CA Bakersfield, CA Commerce, CA Encinitas, CA Fountain Valley, CA Fresno, CA Fullerton, CA Irvine, CA Los Angeles, CA Marysville, CA Riverside, CA Sacramento, CA Salinas, CA San Diego, CA San Jose, CA San Luis Obispo, CA Santa Ana, CA Santa Maria, CA Santa Rosa, CA

30

DELAWARE Dover, DE Georgetown, DE Newark, DE FLORIDA Avon Park, FL Boca Raton, FL Cocoa, FL Davie, FL Daytona Beach, FL Fort Pierce, FL Ft. Myers, FL Gainesville, FL Jacksonville, FL Miami Gardens, FL New Port Richey, FL Orlando, FL Panama City, FL Pembroke Pines, FL Pensacola, FL Plant City, FL Rockledge, FL Sanford, FL St. Petersburg, FL Tampa, FL Winter Haven, FL GEORGIA Albany, GA Athens, GA Atlanta, GA Carrollton, GA Columbus, GA Dahlonega, GA Dublin, GA Dunwoody, GA Lawrenceville, GA Morrow, GA

Oakwood, GA Statesboro, GA Tifton, GA Valdosta, GA HAWAII Laie, HI IOWA Ames, IA Cedar Rapids, IA Iowa City, IA Ottumwa, IA Sioux City, IA Waterloo, IA IDAHO Boise, ID Coeur d ‘Alene, ID Idaho Falls, ID Lewiston, ID Moscow, ID Nampa, ID Rexburg, ID Twin Falls, ID ILLINOIS Carbondale, IL Carterville, IL Champaign, IL Crystal Lake, IL Decatur, IL DeKalb, IL Edwardsville, IL Glen Ellyn, IL Joliet, IL Malta, IL Normal, IL Peoria, IL Springfield, IL Sugar Grove, IL INDIANA Bloomington, IN Columbus, IN Evansville, IN Fort Wayne, IN Gary, IN Indianapolis, IN Kokomo, IN Lafayette, IN Lawrenceburg, IN Madison, IN Muncie, IN New Albany, IN Richmond, IN

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Sellersburg, IN South Bend, IN Terre Haute, IN KANSAS Lawrence, KS Manhattan, KS Overland Park, KS Wichita, KS KENTUCKY Bowling Green, KY Covington, KY Highland Heights, KY Louisville, KY Morehead, KY LOUISIANA Bossier City, LA Lafayette, LA Monroe, LA Natchitoches, LA New Orleans, LA Thibodaux, LA MASSACHUSETTS Boston, MA Bridgewater, MA Danvers, MA Haverhill, MA Holyoke, MA MARYLAND Arnold, MD Baltimore, MD Bel Air, MD Columbia, MD Frederick, MD Hagerstown, MD La Plata, MD Westminster, MD Wye Mills, MD MICHIGAN Ann Arbor, MI Big Rapids, MI Dearborn, MI Dowagiac, MI East Lansing, MI Flint, MI Grand Rapids, MI Kalamazoo, MI Lansing, MI Livonia, MI Mount Pleasant, MI Sault Ste. Marie, MI

Troy, MI University Center, MI Warren, MI MINNESOTA Eden Prairie, MN Mankato, MN Morris, MN MISSOURI Cape Girardeau, MO Columbia, MO Cottleville, MO Joplin, MO Kansas City, MO Kirksville, MO Park Hills, MO Poplar Bluff, MO Rolla, MO Sedalia, MO Springfield, MO St. Joseph, MO St. Louis, MO Warrensburg, MO MISSISSIPPI Goodman, MS Mississippi State, MS Raymond, MS University, MS MONTANA Bozeman, MT Missoula, MT NORTH CAROLINA Apex, NC Asheville, NC Boone, NC Durham, NC Fayetteville, NC Greensboro, NC Greenville, NC Jamestown, NC Misenheimer, NC Pembroke, NC Raleigh, NC Wilmington, NC NORTH DAKOTA Bismark, ND Fargo, ND NEBRASKA Bellevue, NE

Lincoln, NE North Platte, NE Omaha, NE NEW JERSEY Branchburg, NJ Lincroft, NJ Sewell, NJ Toms River, NJ West Windsor, NJ NEW MEXICO Albuquerque, NM Clovis, NM Farmington, NM Portales, NM Santa Fe, NM NEVADA Henderson, NV North Las Vegas, NV NEW YORK Brooklyn, NY Garden City, NY Middletown, NY New York, NY Syracuse, NY OHIO Akron, OH Cincinnati, OH Columbus, OH Fairfield, OH Findlay, OH Kirtland, OH Lima, OH Newark, OH Orrville, OH Rio Grande, OH Toledo, OH Youngstown, OH OKLAHOMA Altus, OK Bethany, OK Edmond, OK Norman, OK Oklahoma City, OK Stillwater, OK Tonkawa, OK Tulsa, OK OREGON Bend, OR Coos Bay, OR

Eugene, OR Gresham, OR Medford, OR Oregon City, OR Portland, OR White City, OR PENNSYLVANIA Bloomsburg, PA Blue Bell, PA Gettysburg, PA Harrisburg, PA Lancaster, PA Newtown, PA Philadelphia, PA Pittsburgh, PA York, PA SOUTH CAROLINA Beaufort, SC Charleston, SC Columbia, SC Conway, SC Greenville, SC Greenwood, SC Orangeburg, SC Rock Hill, SC Spartanburg, SC TENNESSEE Blountville, TN Clarksville, TN Collegedale, TN Gallatin, TN Johnson City, TN Knoxville, TN Memphis, TN Morristown, TN Murfreesboro, TN Nashville, TN TEXAS Abilene, TX Arlington, TX Austin, TX Beaumont, TX Brownsville, TX Commerce, TX Dallas, TX Denison, TX El Paso, TX Houston, TX Huntsville, TX Laredo, TX Lubbock, TX Mesquite, TX

Victoria, TX Weatherford, TX Wichita Falls, TX UTAH Cedar City, UT Kaysville, UT Logan, UT Ogden, UT Orem, UT Salt Lake City, UT VIRGINIA Lynchburg, VA Norfolk, VA Roanoke, VA Virginia Beach, VA WASHINGTON Bellingham, WA Bremerton, WA Ellensburg, WA Olympia, WA Seattle, WA Shoreline, WA WISCONSIN Fond du Lac, WI La Crosse, WI Milwaukee, WI WYOMING Casper, WY Laramie, WY Torrington, WY CANADA Castlegar, BC Edmonton, AB Kamloops, BC Lethbridge, AB London, ON Mississauga, ON Moose Jaw, SK Nanaimo, BC Prince Albert, SK Saskatchewan, SK Saskatoon, SK Toronto, ON Windsor, ON

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HYDAC Technology Corp.

Hydraulex Global

CIRCLE 141

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HYDAC has been active in the field of hydraulics and filtration for more than 50 years and has become a leader in innovative hydraulic products, filtration and lube oil systems. Our interdisciplinary network links engineering expertise, innovation, quality standards and service to provide complete hydraulic solutions for your demands.

Special Advertising Section

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PVS Sensors Inc

Yates Industries

Young Powertech, Inc.

CIRCLE 142

CIRCLE 143

CIRCLE 144

PVS Sensors Inc offers a wide range of pressure, vacuum, temperature and differential switches manufactured in the USA and designed for the Industrial, Mobile, Hydraulic, Pneumatic, Water, Process, Refrigerant, Air Conditioning, Beverage and other associated industries.

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HYDAC TECHNOLOGY CORPORATION 2260 City Line Road Bethlehem, PA 18017 (800) GOHYDAC www.hydacusa.com

Visit our New Website Hydraulex Global is your main source for new aftermarket, remanufactured and surplus hydraulic pumps, motors, valves, servo & proportional valves, cylinders, PTOs and replacement parts. We offer a wide variety of units and components for all your mobile and industrial hydraulic needs covering most hydraulic component manufacturers. We’re here to serve your immediate hydraulic needs. Experience the one-stop shop at hydraulex.com

Yates Cylinders Offer: • H6 Series - Heavy Duty Hydraulic (3000 PSI) • H4 Series - Medium Hydraulic (up to 1500 PSI) • A4 Series - Heavy Duty Steel Air (250 PSI) • A2 Series - Aluminum Air (250 PSI) • Air/Oil Intensifiers • All Stainless Steel Cylinders • Air/Hydraulic Welded & Mill Type Cylinders • Special Cylinders per Customer Supplied Prints and Specifications Yates Industries, Inc. Yates Alabama Division 23050 Industrial Dr. E. 55 Refreshment Place St. Clair Shores, MI 48080 Decatur, AL 35601 586.778.7680 ph 256.351.8081 ph 586.778.6565 fax 256.351.8571 fax

Young Powertech Inc, is a manufacturer and distributor of Hydraulic Motors, Electronic Radio Remote Controls, Hydraulic Gear Pumps and Gear Motors, Planetary Gear Reducers, Hydraulic Radial Piston Motors, Steering Control Units and Steering Valves, Steering Columns, Wheel and Track Drives as well as other Mechanical Components for mobile, marine, mining and industrial applications. Young Powertech Inc. was started by Exclusive North people with decades of experience American Partner of: in the field and are dedicated to bringing products and service to the customer at a higher level.

TECH DIRECTORY 2014

31

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lS eF yst req em uen s rs c ctr y -A Dri ic M C ves o Ele tor ctr sica DC lA En ctu clo ato sur rs es Fie ldb us Tec Fie hn ldb olo us gie Tec sFie hn AS olo ldb I gie us Tec sFie De hn vic olo ldb eN gie us et sTec Fie Eth hn ldb o ern log Pro us T e ies t IP fiD ech - In riv ter e nolog link Fie i e sldb BT Pro us fib Tec us Flo hn D olo wm P, gie ete srs Hu Se -V ma r a c ria os nble Ma Are Jo chi yst a n e ick Int erf -A Jo ace nal yst og s( ick HM S ign - In I’s) al Jo teg yst ral ick A m -N plifi Jo on yst er - co ick nta -P c tin Lig ote g ht (Ha nti Cu om ll) rta ete ins Lig r hts , Il lum Po ina ten tio tio n me ter sLin ear

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1A Total Safety A & A Manufacturing Company Inc. ABZ, Inc. Ace Wire Spring & Form Co., Inc. Activant Adsens Technology, Inc. Airline Hydraulics Air Logic Airmo, Inc. ALA Industries, Ltd. All Sensors Corp.

Allen Orton LLC Allenair Corporation Alliance Sensors Group Almo Manifold & Tool Company American Aerospace Controls, Inc. American Cylinder Co., Inc. American High Performance Seals American Sensor Technologies, Inc. AMETEK Automation & Process Technologies Anderson Metals Corp., Inc. Anfield Sensors Inc. Applied Industrial Technologies ARGO-HYTOS, Inc. ASCO Numatics Ashcroft Inc. ASI Inc. Assured Automation ASP, Inc. Astrodyne Corporation ATOS S.P.A. Attica Hydraulic Exchange/Hydraulex Global Automation Products, Inc. - Dynatrol Div. Automation Systems Interconnect, Inc. Aventics Corporation (formerly Bosch Rexroth Pneumatics) AW-Lake Company Axiomatic Technologies Corporation Balluff, Inc. Behringer Corp.

Beswick Engineering Co., Inc. Bimba Manufacuring Company Birmingham Hydraulics Inc. Bondioli & Pavesi, Inc. Bosch Rexroth Corporation Brand Hydraulics Bray Controls, Div of BRAY Int’l Inc. Brennan Industries Inc. Bucher Hydraulics, Inc. Burkert Fluid Control Systems CADSYM Canfield Connector Canimex inc.

Central Illinois Mfg. Co. (Cim-Tek) Filtration) Certified Power, Inc. CIM-TEK Filtration Clippard Instrument Laboratory, Inc. CMC Marine, Inc. Coilhose Pneumatics Comatrol Command Controls Corp.

Component Sourcing International LLC Concentric Rockford Inc. Continental Hydraulics ControlAir, Inc. Control Enterprises, Inc. Controlled Fluids, Inc. Controlled Motion Solutions, Inc. Cox Instruments CPV Manufacturing, Inc. Cross Mfg. Inc. CS Unitec, Inc. Custom Control Sensors Inc. Custom Sensors & Technologies (CST) Cyber-Tech, Inc. Dakota Fluid Power

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TECH DIRECTORY 2014

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34

lS eF yst req em uen s rs c ctr y -A Dri ic M C ves o Ele tor ctr sica DC lA En ctu clo ato sur rs es Fie ldb us Tec Fie hn ldb olo us gie Tec sFie hn AS olo ldb I gie us Tec sFie De hn vic olo ldb eN gie us et sTec Fie Eth hn ldb o ern log Pro us T e ies t IP fiD ech - In riv ter e nolog link Fie i e sldb BT Pro us fib Tec us Flo hn D olo wm P, gie ete srs Hu Se -V ma r a c ria os nble Ma Are Jo chi yst a n e ick Int erf -A Jo ace nal yst og s( ick HM S ign - In I’s) al Jo teg yst ral ick A m -N plifi Jo on yst er - co ick nta -P c tin Lig ote g ht (Ha nti Cu om ll) rta ete ins Lig r hts , Il lum Po ina ten tio tio n me ter sLin ear

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Davies Molding Del Equipment Limited DEL Hydraulics DELTA Computer Systems, Inc. Differential Pressure Plus, Inc. Donaldson Company Inc. Duplomatic Hydraulics Dwyer Instruments, Inc. Dylix Corporation Dynamic Fluid Components, Inc. DynaQuip Controls EAO Corporation Eaton Hydraulics Electro-Sensors Inc. Electroswitch Ellison Sensors, Inc. Elma Electronic Emmegi Heat Exchangers, Inc. Energy Manufacturing Co., Inc. Enfield Technologies Engineered Sales, Inc. Engineering Technology Services, LLC Exair Corporation Fabco-Air, Inc. Falcon Surplus FAMIC Technologies Inc. Faster Inc. FCI Automation Feroy Company, Inc. Flint Hydraulics, Inc. Flodraulic Group Flodyne Controls, Inc. Flow Technology Flow-Tek, A Subsidiary of BRAY Int’l Inc. Fluid Line Products, Inc. Fluid Power Associates, Inc. Fluid Power Connections Fluid Power, Inc. Fluid Power Products, Inc. Fluidtechnik USA,Inc. FluiDyne Fluid Power Force America Futek Advanced Sensor Technology Inc. FW Murphy Galtech Canada Inc. Gefran Gems Sensors & Controls Gemu Valves Global Servo Hydraulics Granzow GS Hydraulics, Inc. Hach Flow Meter Products & Services HAWE Hydraulics Haydon Kerk Motion Solutions, Inc. Heavy Motions Inc. HED Inc. (Hydro Electronic Devices) Hedland Flow Meters Helium Leak Testing, Inc. Hercules Sealing Products Heypac Inc. High Country Tek, Inc. Himmelstein, S. & Co. HKX, Inc. HL Hydraulic, Inc. HMI Systems Hoffer Flow Controls Huade - USA Humphrey Automation Inc. Humphrey Products Company HUSCO International Inc. Hydac Inc. Hydradyne Hydraulics LLC Hydramation, Inc. Hydraulic Management Group, LLC Hydraulic Resources, Inc.

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TECH DIRECTORY 2014

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Hydraulic Supply Co. Hydraulics International Inc. Hydrauliques Continental HyFlow Controls Inc. IEEE, Inc. IFM Efector Inc. Industrial Hydraulic Services Industrial Nut Corp.

Industrial Servo Hydraulics, Inc. Industrial Specialties Mfg., Inc. Innotek Corporation Integrated Hydraulics, Inc. International fpa IQ Valves (Formerly Teknocraft) ITT JH Technology, Inc. J.R. Merritt Controls Inc. Kanamak Hydraulics Inc. Kavlico Keller America, Inc. Kraft Fluid Systems, Inc. Kurz Instruments, Inc. La-Man Corporation LCR Electronics Lovejoy Hydraulics Lynch Fluid Controls, Inc. M & M Rogness Equipment Co. Macro Sensors Madison Company Magnetek Maradyne Corp./Marion Fluid Power Div. Mark Hydraulic Company Inc. Marsh Bellofram Marvel Consultants Inc. Max Machinery Measurement Specialties Micheller and Son Hydraulics, Inc. Mid-West Instrument MKS Instruments, Inc. Mobile Hose & Hydraulic Supply Moog Motion Industries MP Filtri USA, Inc. MROStop LLC MTS Sensors MTS Systems Corporation Murrelektronik, Inc. Nachi America NBB Controls, Inc. NC Servo Technology Net Motion Inc. Norgren Norstat Inc. NOSHOK, Inc. Nott Company Novotechnik U.S. Inc. Nycoil Company OEM Controls, Inc. Oil-Rite Corporation O’Keefe Controls Co. Omega Engineering Optex-FA Panasonic Electric Works Corp. of America Parker Hannifin Corp., Hydraulic Valve Div. PCB Piezotronics Inc. P.E.P. Peter Paul Electronics PHD, Inc. Pico Electronics Pinnacle Systems, Inc. Pneumatic Cylinders & Couplers Inc. (PNEU C&C) Poclain Hydraulics Inc. Pressroom Electronics Pressure Components Inc. Pressure Controls Inc.

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TECH DIRECTORY 2014

37

38

lS eF yst req em uen s rs c ctr y -A Dri ic M C ves o Ele tor ctr sica DC lA En ctu clo ato sur rs es Fie ldb us Tec Fie hn ldb olo us gie Tec sFie hn AS olo ldb I gie us Tec sFie De hn vic olo ldb eN gie us et sTec Fie Eth hn ldb o ern log Pro us T e ies t IP fiD ech - In riv ter e nolog link Fie i e sldb BT Pro us fib Tec us Flo hn D olo wm P, gie ete srs Hu Se -V ma r a c ria os nble Ma Are Jo chi yst a n e ick Int erf -A Jo ace nal yst og s( ick HM S ign - In I’s) al Jo teg yst ral ick A m -N plifi Jo on yst er - co ick nta -P c tin Lig ote g ht (Ha nti Cu om ll) rta ete ins Lig r hts , Il lum Po ina ten tio tio n me ter sLin ear

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Pressure Systems, Inc. Progressive Hydraulics, Inc. Proportion-Air, Inc. Pulsafeeder, Inc. PWM Controls Inc. PVS Sensors Inc. Rego Cryo-Flow Products Rite pro, Inc., A Subsidiary of BRAY Int’l Inc. Robeck Fluid Power Co. Rota-Cyl Corporation Rupe’s Hydraulics Sang-A Pneumatic Corp.

Schmalz Inc. Schroeder Industries Schunk Inc. Scorpion Technologies Ltd. Seal Master Corporation Semiconductor Circuits Inc. Servo-Tek Products Company Inc. Seventy-Three Mfg. Co. Inc. S.G. Morris Co. SICK, Inc. Sierra Instruments, Inc. Simerics Smalley Steel Ring Co. Source Fluid Power Spartan Scientific SPC Sang-A Pneumatic Corp.

Spectronics Corporation Spencer Fluid Power Spirax Sarco Stanley M. Proctor Company Suco Technologies, Inc. Sun Hydraulics Corporation SVF Flow Controls, Inc. Swift-Cor Precision, Inc. Switches Unlimited Switching Solutions Inc. SymCom, Inc. The Knotts Company The Oilgear Company Thomas Products LTD Titan Inc. TopWorx UFI Filters UHI, LTD Ultraflo Corporation Unique Automation LLC United Electric Controls Universal Grinding Corp.

Universal Hydraulics International, LTD Vaccon Company Inc. Validyne Engineering Corp.

VEST, Inc. Vindum Engineering, Inc. Voith Turbo Inc. VOSS Fluid GmbH Wandfluh of America, Inc. Webster Instruments WEBTEC WEH Technologies Inc. Weiss Instruments, Inc. West Coast Fluid Power Western Hydrostatics, Inc. Western Integrated Technologies, Inc. WIKA Instrument Corporation Wilson Company Winters Instruments Wojanis Supply Co. Womack Machine Supply Company WP Associates Young Powertech Inc. Yuken/ALA Industries

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TECH DIRECTORY 2014

39

SIMULATION

Do’s & Don’ts

Don’t TAKE A

GUESS! P ower on, fingers crossed, and hope for the best… The practices of guessing and “we will see how it works” have no place in modern design. Competition pressure in the drive market, time, and cost limitations force fluid power engineers to abandon “good old” trial-anderror methods and replace them with more efficient simulation-based fast prototyping.

SIMULATION IN FLUID POWER A typical hydraulic circuit consists of a large number of interacting components: transmission lines,

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1

ACCELERATE PROTOTYPING AND VALIDATION OF HYDRAULIC SYSTEMS USING NUMERICAL SIMULATION

By Jan Komsta and Paul Stavrou, Bosch Rexroth Corp.

pumps, accumulators, motors, cylinders, flow and pressure control valves, along with other related equipment. Each of these elements is characterized by individual static and dynamic properties, defined by mechanical design, actuation method, mechanical response, fluid properties, and other factors. It is relatively simple to predict the response of a single component, for example a proportional valve or pump swash plate, especially when the manufacturer provides sufficient data in the product data sheet. However, in many cases, it may be difficult to predict the dynamic response of the overall system along with interactions

KEEP THE MODEL AS SIMPLE AS POSSIBLE, AS COMPLEX AS NECESSARY. Focus on the simulation’s targets, and focus on critical system components and subsystems that need to be included in the model. Often there is no need to simulate each individual valve or orifice in the system.

Appropriately simplified and reduced models are easier to analyze and evaluate. Furthermore, simplifying the simulation can reduce the risk of input data errors and can shorten overall simulation times.

between dynamic subsystems. The challenge arises from the inherent nonlinear behavior of fluid power systems, resulting from the distinctive physical properties of oil compressibility and the square-root resistor law governing flow across a valve’s spool-throttling orifices. In the past, predicting the performance of a hydraulic drive was limited to static calculations and highly simplified linearized dynamic models based on differential calculus. The last two decades have brought tremendous progress in numerical computation and simulation technologies.

Today powerful simulation tools are available to design engineers, making advanced analysis of hydraulic systems’ behavior and performance readily accessible.

Due to high system complexity, performing a computer simulation can be a handy tool when working on a new system concept or troubleshooting an existing problem.

Using a virtual model in an appropriate simulation program offers a completely new insight to the system’s properties, allowing validation and optimization of the design.

System modeling and simulation is often performed for any number of reasons. Some of the common ones are • feasibility study and reality check for new designs; • verification and optimization of the component selection and system concepts; • prediction and analysis of system dynamic behav-

ior, including hydraulics, mechanics, process (metal forming, injection molding, etc.) and closed-loop control algorithms (motion control, force control, etc.); • analysis of machine productivity (achievable cycle rates), dynamic performance of the closed-loop control, accuracy, energy efficiency; and • safety analysis under worse-case scenarios.

Simulation is one of the easiest ways to evaluate dynamic and nonlinear characteristics of electro-hydraulic drives, and is an efficient and inexpensive way to validate new ideas and concepts without the need for testing physical prototypes. This helps to reduce the risk of expensive field redesign and retrofitting of systems that do not meet required performance and/or stability criteria. The end result is that advanced simulation-aided prototyping drastically shortens application development time.

HOW DO YOU APPROACH SIMULATION OF A HYDRAULIC SYSTEM? Depending on the goal of the simulation, an engineer can select from a number of commercially available simulation tools dedicated to hydraulic systems. Some examples of available products are Mathworks Simscape, ITI SimulationX, AMESim, and Easy5. Each program offers different component libraries, levels of the detail,

2 TEST YOUR SIMULATION MODEL. Divide the model into small subsystems (actuators, power units, control blocks, etc.). Test each of the subsystems separately as you build the overall system model. This allows validation of the model in a step-bystep manner, similar to a real-world start-up.

Steps such as verifying the sub-model of the power unit (checking pump flows, pressures, and setting the pump control) can be done first, followed by control valves and hydraulic actuators. In each step, valve flows, pressure drops, and pressure spikes in the hydraulic lines can be reviewed, as well as cylinder motions and other related functions can be noted.

3 Fig. 1: Example of a simulation model of a hydrostatic drive, using Bosch Rexroth’s Simster program.

The simulation includes detailed models of a servo pump, boost and flushing unit, hydraulic hoses, motor, mechanical load, and closed-loop motion control.

Simulation allows investigation of various system states, such as changes in pressure or angular position of the motor.

DO NOT UNDERESTIMATE THE INFLUENCE OF HYDRAULIC LINES ON SYSTEM DYNAMICS. Consider the distance between the power unit, control manifolds, and actuators. The simulation should include the dimensions of hoses and lines, as well as the dynamic characteristics of those elements.

TECH DIRECTORY 2014

41

and flexibility in the model’s parameterization. Bosch Rexroth has developed a range of tools for in-house use (MOSIHS, Simster, and HYVOS) that are tailored to the requirements of application support and development.

Before starting a simulation, the objectives of simulation study need to be precisely specified. What are the main goals of the simulation? What questions need to be answered by simulation? One example is investigation of the response of a closed-loop control under specified load scenarios. Other examples would be to compare energy consumption of two different system variants or presenting the functionality of a new hydraulic schematic.

One pitfall is when application engineers specify simulation requirements too broadly. An example would be a request form stating, “The system should be simulated.”

This would be too broad and general. Clear objectives help focus the simulation effort on efficient problem solving.

When planning or performing a simulation, it should be noted that a basic rule, which applies to every calculation, is “garbage in = garbage out.” This results in a simulation being as meaningful and accurate as the data that was provided. Experience shows that one of the most difficult problems in the overall simulation process is obtaining meaningful information about the mechanical loads (reaction forces due to forming process, gravitational and friction forces, etc). One critical fact concerns the mechanical inertia of the load to be actuated by hydraulic drive. The mechanical loads and inertias are critical when simulating dynamics and the closed-loop control since they determine the response of the system and performance of the closed-loop controls. An example is simulating positioning accuracy of a cylinder drive, but it makes little sense if the opposing process and frictional forces are unknown. Most model

parameters can be obtained from the design documentation, CAD drawings (mechanical inertias), or—if simulating an existing application—“system identification” based on measured values (pressure, position, velocity, etc.). Unfortunately, in many cases, the engineer performing the simulation has to rely on experience and engineering “know-how.” The simulation input data should always be critically reviewed by a system designer and the application engineer.

CO-SIMULATION OF COMPLEX MECHANICAL AND HYDRAULIC SYSTEMS In simple simulations, actuated mechanical systems can be modeled as “lumped” elements, which are simple single elements that represent a more complex set of elements. Often simple spring mass dampers are used in a hydraulic simulation to predict a system’s overall dynamic performance. This only works when a known mechanical resonance is known, dominant, and well defined. More complex mechanical systems, such as multi degree-offreedom manipulators, toggle drives, moving platforms, and other systems, have multiple resonant modes within the mechanical system and are best modeled using multibody dynamic simulation software (MBS). MBS models of complex mechanical systems can take into account the mechanical inertias and flexibilities of the various modeled elements. The MBS model can provide the torque or force inputs from elements, such as hydraulic cylinders, to drive the mechanical system and see the resulting reaction.

Combining a simulation of an electro-hydraulic system and an MBS model allows analysis of the overall motion system performance, including interactions between the dynamics of a hydraulic drive, the closed-loop control, and resonances of the actuated mechanical structure.

Fig. 2: Co-simulation of blast furnace distributor includes model of electro-hydraulic drive system, closed-loop control algorithm, and MBS model of the chute assembly.

4 CHECK PRESSURES IN THE SYSTEM, and watch for highpressure spikes, pressure drops, and possible cavitation in critical areas of the system.

5 BE SKEPTICAL AND DOUBLE-CHECK RESULTS. Verify component catalog data, and review the operational conditions and compare them to the nominal published data. Check if simulated values are within the component specification with regard to allowable pressure, maximum permissible valve flow, and valve power limitations.

6 CALCULATE STATIC PROCESS VALUES, such as forces, flows, static pressures, etc., prior to simulation.

These calculated values can be used to evaluate the validity of the simulation results.

7 KNOW THE BASIC MATHEMATICS behind the component models (dynamics of a valve, pressuredependant bulk modulus of hydraulic fluid) and understand the settings of the numerical solver and the influence on the simulation results.

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Fig. 3: Chute assembly (left) and simulation results (right) depicting the piston position and piston velocity during 90-second distributor duty cycle

An example of such an MBS-hydraulics cosimulation is a study by Bosch Rexroth of a blast furnace hydraulic distributor designed and built

by Woodings Industrial in Mars, Pa. A hydraulic distributor, as seen in Figs. 2 and 3, provides two functions: rotation and tilting a chute to deposit layers of iron ore and coke into a blast furnace. The precision of the deposition of the materials is critical in controlling the melting process. The blast furnace can operate with increased efficiency based on the precision of the layers of the deposited materials charged into the furnace.

The hydraulic and control systems have to react quickly to load changes and other disturbances in order to maintain high position accuracy of the chute. Additionally, a tight position tolerance between four differential cylinders must be maintained. A major challenge was a low natural frequency of hydraulic cylinder drive due to high mechanical inertia of the chute and long hydraulic lines between control valves and cylinders. The hydraulic system acts like a mass damper spring with a relatively low stiffness and damping, making accurate motion control difficult. To verify the targeted accuracy and repeatability of the Rexroth hydraulic drive system could be met, a complex multi-domain simulation was performed. The distributor chute hydraulic circuit and controls designed by Rexroth were simulated using “MOSIHS�, a proprietary simulation program for hydraulic and mechanical systems and controls. All relevant 3D CAD models of the Woodings-sourced components, such as the chute and the rotating distributor head mechanical systems, were imported into

a commercially available MBS program that is coupled to the MOSIHS simulation tool. The co-simulation helped to optimize the hydraulic circuit design and component selection and the closed-loop controls. The simulation resulted in the need for a specialized control algorithm using load feedback information to effectively dampen the system oscillations and provide optimal performance. The simulation also allowed the design engineers to analyze and develop a better understanding of how the load forces act on the chute and how they could affect end-point accuracy.

CONCLUSIONS The ability to accurately simulate hydraulic drives can increase the success of many complex applications. Validating design concepts, and investigating worst-case conditions and modes of operation can reduce operational and financial risks. Being able to verify performance criteria during the proposal and design stages can result in higher performing and more competitive designs.

For more information JAN KOMSTA, PH.D., IS MANAGER OF NEW TECHNOLOGIES, AND PAUL STAVROU IS TECHNOLOGY MANAGER FOR BOSCH REXROTH. VISIT WWW.BOSCHREXROTH-US.COM.

CIRCLE 146

TECH DIRECTORY 2014

NFPA NEWS

By Eric Lanke, CEO, NFPA

FLUID POWER’S ROLE IN OUR NATION’S ENERGY-EFFICIENT FUTURE: PART 8

TECHNOLOGIES DRIVING THE U.S. TO OUR ENERGY FUTURE

By Eric Lanke, CEO, NFPA

This article is eighth in a series describing NFPA’s actions focused on the development of a program within the U.S. Department of Energy (DOE) that can fund and focus on energy-efficiency improvements using fluid power technology. The envisioned program would be partly research-focused, helping to improve the design and maintenance of existing fluid power systems with current technologies and techniques.

I

f you’ve been following this series, you know that we have been successful in establishing that fluid power research and education represents significant opportunities to reduce the amount of energy consumed in the United States, especially in the industrial sector. And, as I wrote last time, several interactions with what is now the Advanced Manufacturing Office (AMO) of the U.S. Department of Energy (DOE) resulted in an invitation for us to get engaged with the U.S. Council of Competitiveness.

The U.S. Council of Competitiveness is a non-partisan, non-governmental organization composed of peer corporate CEOs, university presidents, labor leaders, and national laboratory directors. It works to set an action agenda to drive U.S. competitiveness while generating innovative public policy solutions for a more prosperous America. One of its core principles identifies sustainable energy—exploiting domestic resources and using energy efficiently—as foundational to U.S. prosperity, and under that principle, the Council has entered into a partnership with the U.S. DOE. The partnership is called the American Energy & Manufacturing Competitiveness Partnership (AEMC), and its focus is currently on something the DOE is calling the Clean Energy Manufacturing Initiative (CEMI). Together, the AEMC and the CEMI aim

to increase U.S. manufacturing competitiveness across the board by increasing energy productivity and by investing in technologies and practices to enable U.S. manufacturers to increase their competitiveness through energy efficiency.

This is where we think fluid power could possibly come in—as one of the technologies that will enable U.S. manufacturers to increase their competitiveness through energy efficiency.

We’ve asked fluid power representatives to attend several meetings of the AEMC, including a series of regional summits they held, where they sought input on how the CEMI could best achieve its aims. These regional meetings culminated in December 2013 in a national summit held in Washington, DC. I attended this event—along with about 500 people—many of them high-ranking government officials and program administrators. The focus was on continuing the dialogue with people outside the Beltway, and they accomplished that through a series of presentations and panel discussions.

The most impactful for our industry was the one they titled “Technologies Driving the U.S. to Our Energy Future.” Here’s the description from the summit program materials: “Over the last several years, global investment in the clean energy sector has risen nearly fivefold, growing from $54 billion in 2004 to $269 billion worldwide in 2012. The United States faces

a stark choice: the energy technologies of the future can be developed and manufactured in America for export around the world, or we can cede global leadership and import those technologies from the rest of the world. The panel brings together leaders that create, enable, or deploy the technologies that drive U.S. competitiveness in the production of clean energy products and/ or increase energy productivity across the U.S. industrial base to answer the questions: (1) What are the technologies that the U.S. needs to focus on to ensure leadership in the clean energy sector? (2) How do advanced manufacturing technologies drive energy efficiency throughout the U.S. industrial base?”

Fluid power should undoubtedly be one of the technologies, and I said as much at the summit. Not only do we have documentation that shows the significant energy consumption profile of fluid power systems, but we also are still an industry where the most advanced technology is manufactured in the United States. We have a leadership position, and deeper investment into innovation and education can help make sure we don’t lose it.

It is sometimes difficult to know how much impact you’re having when participating in these large sessions, but every opportunity we have to speak up for fluid power is an important one, and we’ll keep taking advantage of them.

The intent of this series is to keep NFPA members better informed about efforts in this regard, and also to seek their help in advocating for the envisioned program. Please watch this space for more background on this issue, as well as regular updates on the Association’s progress. If you would like to become more involved, please contact Eric directly at 414-778-3351 or elanke@nfpa.com. Getting industry leaders engaged in this effort will be critical to its ultimate success.

44

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markets, and economic indicators.

Expert Analysis and Hard Data Dynamic conferences, meetings and webcasts keep our members up to date on the latest economic conditions, emerging trends and industry insights for today’s ever‐changing economic climate.

You have the Ideas, We Provide the Tools From point‐and‐click Excel‐based software that automates time‐consuming calculations, trend analysis, and custom forecasting to a user‐friendly web dashboard that allows members custom access to industry information.

Find out how to become part of NFPA by calling Leslie Miller at 414‐778‐3369, or email at lmiller@nfpa.com.

HYDRAULIC AND PNEUMATIC INDUSTRY TRENDS FROM NFPA

Pneumatic, Mobile, and Industrial Hydraulic Orders Index 200.0 180.0

Plan Your Next Move

160.0

NFPA’s industry reports, outlook surveys, forecasts, and data sources allow our members to understand trends and anticipate change with a variety of trend graphs and data analysis for fluid power products, customer markets, and economic indicators.

140.0 120.0 100.0 80.0

Expert Analysis and Hard Data

You have the Ideas, We Provide the Tools

Jun‐14

Mar‐14

Dec‐13

Jun‐13

Sep‐13

Mar‐13

Sep‐12

Dec‐12

Jun‐12

Dec‐11

Mobile Hydraulic

Industrial Hydraulic

Each point on this graph represents the most recent 12 months of orders compared to the previous 12 months of orders. Each point can be Each point on this graph represents the most recent 12 months of orders compared to the previous 12 months of orders. Each point can be read as a percentage. For example, 102.6 (the June 2014 level of the industrial hydraulic series) indicates that industrial hydraulic read as a percentage. For example, 102.6 (the June 2014 level of the industrial hydraulic series) indicates that industrial hydraulic orders orders received from July 2013 to June 2014 were 102.6% of the orders received from July 2012 to June 2013. (Base Year 2013 = 100) received from July 2013 to June 2014 were 102.6% of the orders received from July 2012 to June 2013. (Base Year 2013 = 100)

Total ‐ Hydraulic and Pneumatic Shipments Total - Hydraulic and Pneumatic Shipments

Fluid Power Industry Growth Trend

100.0 90.0

Much more information is available to NFPA members, which allows them to better understand trends and anticipate change in their market and the customer markets they serve. Contact NFPA at 414-778-3344 for more info. Find out how to become part of NFPA by calling Leslie Miller at 414-7783369, or email at lmiller@nfpa.com.

Mar‐12

Sep‐11

Jun‐11

Dec‐10

Mar‐11

Sep‐10

Jun‐10

Mar‐10

Dec‐09

Jun‐09

Sep‐09

Total Pneumatic

From point-and-click Excel-based software that automates time-consuming calculations, trend analysis, and custom forecasting to a user-friendly web dashboard that allows members custom access to industry information.

The latest data published by the National Fluid Power Association shows industry shipments of fluid power products for July 2014 increased 10.4% compared to June 2013, and remained the same when compared to last month. Industrial hydraulic, mobile hydraulic and pneumatic shipments increased in June 2014 when compared to June 2013. Pneumatic shipments increased, while mobile hydraulic and industrial hydraulic shipments decreased when compared to last month. These charts are drawn from data collected from more than 80 manufacturers of fluid power products

by NFPA’s Confidential Shipment Statistics (CSS) program.

40.0

Mar‐09

60.0

Dynamic conferences, meetings and webcasts keep our members up to date on the latest economic conditions, emerging trends and industry insights for today’s ever-changing economic climate.

Dec‐08

The National Fluid Power Association (NFPA) is the leading source of hydraulic and pneumatic industry data.

Pneumatic, Mobile and Industrial Hydraulic Orders Index

Total ‐ Hydraulic and Pneumatic Shipments 120.0 120.0

110.0

110.0 100.0

90.0

80.0

80.0

70.0 70.0 60.0

60.0

50.0 50.0

Total Fluid Power Total Fluid Power

Total Pneumatic Total Pneumatic

Total Hydraulic Total Hydraulic

This graph of 12‐month moving averages shows that in July 2014, both hydraulic shipments and pneumatic shipments increased. (Base Year This graph of 12‐month moving averages shows that in July 2014, both hydraulic shipments and pneumatic shipments increased. (Base Year This graph of 12-month moving averages shows that in July 2014, both hydraulic shipments and pneumatic shipments increased. (Base 2013 = 100) 2013 = 100) Year 2013 = 100)

Shipments – Cumulative year‐to‐date % change (2014 vs. 2013) Shipments – Cumulative year‐to‐date % change (2014 vs. 2013) Shipments - Cumulative Year-To-Date % Change (2014 vs. 2013) Total Fluid Power

Total Hydraulic

Total Pneumatic

Shipments

Shipments

Shipments

5.6

6.6

5.5

May‐14

5.1

6.0

4.5

Jun‐14

5.7

6.4

5.6

Total Fluid Power

Apr‐14

Apr‐14

May‐14

Shipments

5.6 5.1

Total Hydraulic Shipments

6.6 6.0

Total Pneumatic Shipments

5.5 4.5

Jun‐14 5.7 6.4 refer to the percent difference between 5.6 The table above is expressed in terms of cumulative percent changes.These changes refer to the percent difference between the relevant These changes the relevant The table above is expressed in terms of cumulative percent changes. cumulative total for 2014 and the total for the same months in 2013. For example, the June pneumatic shipments figure of 5.6 means that for cumulative total for 2014 and the total for the same months in 2013. For example, the June pneumatic shipments figure of 5.6 means that The table above is expressed in terms of cumulative percent changes.

These changes refer to the percent difference between the relevant the calendar year through June 2014, pneumatic shipments increased 5.6% compared to the same time period in 2013. (Base Year 2013 = 100) for the calendar year through June 2014, pneumatic shipments increased 5.6% compared to the same time period in 2013. (Base Year 2013

cumulative total for 2014 and the total for the same months in 2013. For example, the June pneumatic shipments figure of 5.6 means that = 100) for the calendar year through June 2014, pneumatic shipments increased 5.6% compared to the same time period in 2013. (Base Year 2013 = 100)

Fluid Power Industry Growth Trend

Fluid Power Industry Growth Trend

TECH DIRECTORY 2014

The latest data published by the National Fluid Power Association shows industry shipments of fluid

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1. Do you specify, select, or influence the purchase of components & systems on new or existing machinery?

03  Yes 04  No If yes, in which technologies? (check all that apply) 05  Hydraulic 06  Pneumatic 07  Vacuum 08  Electronic Controls 09  None of these 2. What is your primary job title? (check all that apply) 10  Administration 11  Plant Operations 12  Engineering 13  Technical 14  Mechanical 15  Purchasing 16  Other

A  1-19

B  20-49

C  50-99

D  100-249

J  Snow Vehicles, Ski Lifts K  Steel Plants & Rolling Mills L  Truck & Bus Industry M  Textile Machinery N  Woodworking Machines O  Other (specify) P  Fluid Power Industry

E  250-499

5. What is the primary business activity at this location?

In the Fluid Power Industry: 56  Manufacturer 57  Distributor 58  Education Outside the Fluid Power Industry: 59  Original Equipment Manufacturer (OEM) 60  End User of Fluid Power Products 6. In which region does your company do business? (check all that apply) 61  East 62  Midwest 63  Southeast 64  Southwest

65  West

66  National

67  International

7. My Company should be advertising in or submit an article to the Fluid Power Journal. Please contact this person: Name: ___________________________________ Title: _________________________________ Phone: ______________________________ 8. I wish to receive a free subscription to Fluid Power Journal:

01  Yes

02  No

______________________________________________________________________________________________________________________ Signature Date 9. I would like more information on the following products: (Please check all that apply) 800  Accumulators 805  Filters 808  Hose & Tubing 801  Accessories 806  Gauges & Sensors 809  Hydraulic Fluids 802  Electronic Controls 807  Heat Exchangers, 810  Motors 803  Couplings & Fittings

Heaters, Aftercoolers, 811  Pumps 804  Cylinders Dryers 812  Seals & Packing 10. I plan on purchasing the above products in the next: 68  0-3 months 69  3-6 months 70  6-9 months

71  12+ months

Please send Fluid Power Society Information (please check all that apply) 897  Membership 898  Certification 899  Training/Education

813  Vacuum 814  Valves 815  Software

F  500-999

G  1000+

www.fluidpowerjournal.com

4. Number of employees at this location?

B  Material Handling Equipment C  Mining Machinery D  Packaging Machinery E  Plastic Machinery F  Presses & Foundry G  Railroad Machinery H  Road Construction/Maintenance Equipment I  Simulators & Test Equipment

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3. Which of the following best describes your market focus?

A  Aerospace I  Forestry B  Agricultural Machinery J  Furnaces C  Automotive K  Gas & Oilfield Machinery D  Civil Engineering L  Heavy Construction & Equipment E  Cranes M  Military Vehicles F  Drills & Drilling Equipment N  Construction & Utility Equipment G  Flame Cutting/Welding O  Machine Tools Equipment P  Government Related H  Food Machinery A  Marine & Offshore Equipment

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Which edition would you like to receive?  Print  Digital  Both 1. Do you specify, select or influence the purchase of components & systems, on new or existing machinery? 03  Yes 04  No. If yes, which technologies? (check all that apply) 05  Hydraulic 06  Pneumatic 09  None of These 07  Vacuum 08  Electronic Controls 2. What is your primary job title? (check only one) 10  Administration: Chairman, Pres., V.P., Sec., Tres., G.M., Owner,

Bus. Mgr., Dir., etc.

11  Plant Operations: VP of Mfg/ Oper/ Prod., Plant Mgr./ Dir. Mgr.,

Supv./ Supt./ Foreman/ Safety Dir., etc.

12  Engineering: V.P. Eng., Eng., Des. Eng., Dir. of Eng., Staff Spec.,

Chief Eng., Senior Eng., Maint/Prod. Eng., etc.

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(View a sample of our PAPERLESS digital edition at www.fluidpowerjournal.com) 4. What is the primary business activity at this location?

In the Fluid Power Industry Outside the Fluid Power Industry 56  Manufacturer 57  Distributor 58  Education 59  Original Equipment Manufacturer (OEM) 60  End User of Fluid Power Products 61  Other: (please specify)______________________________________ 5. Which of the following best describes your market focus?

A  Aerospace A  Marine & Offshore Equipment B  Agricultural Machinery B  Material Handling Equipment C  Automotive C  Mining Machinery D  Civil Engineering D  Packaging Machinery E  Cranes E  Plastic Machinery F  Drills & Drilling Equip.

F  Presses & Foundry G  Flame Cutting/Welding Equip. G  Railroad Machinery H  Food Machinery H  Road Construct/Maint. Equip.

I  Forestry I  Simulators & Test Equipment J  Furnaces J  Snow Vehicles, Ski Lifts K  Gas & Oilfield Machinery K  Steel Plants & Rolling Mills L  Heavy Construction & Equip. L  Truck & Bus Industry M  Military Vehicles M  Textile Machinery N  Construction & Utility Equip. N  Woodworking Machines O  Machine Tools O  Other (specify)_____________ P  Government Related P  Fluid Power Industry

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