Fluid Power Journal June 2025

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Features

06 An Overheating, Closed-Loop Hydraulic System

A case study based on actual events.

» TEST YOUR SKILLS

09 Understanding Basic Fluid Power & Electrical Symbols and Their Analogies

Stay sharp with this monthly lesson from the IFPS's study guide.

10 Hydro-Mechanical vs Electro-Hydraulic Solutions

As presented by Dr. Medhat Khalil, Director of Professional Education at the Milwaukee School of Engineering.

» COVER STORY

18 Anti-Cavitation Valve Applications

Engineers combat cavitation in hydraulic systems.

22 Electrification & Hybrid Trends in Heavy Construction Equipment

Advancing efficiency, performance, and sustainability in construction.

24 Flange End Fittings

A reliable solution for securing hydraulic systems with flange end fittings.

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.

Compressed Air Filtration

Brochure offers a comprehensive overview of the company’s complete line of compressed air filtration products. Highlighted is the patented family of Extractor/Dryers. These two-stage, point of use filters remove contaminates to a 5-micron rating with flow ranges of 15 to 2,000 scfm. Additional products available include the SuperStar Membrane Dryer, .01 Micron Filter, Refrigerated Extractor/Dryer, and much more.

La-Man Corporation

800.348.2463 www.laman.com

Motion Repair & Services: Local Support, Reliable Solutions

Get timely and reliable repair solutions from our conveniently located shop facilities throughout the U.S., Canada and Mexico. Motion Repair & Services comprises a robust network of service centers, expert engineering teams and skilled field technicians. We specialize in mechanical, electrical, fluid power, process pumps, mill services, and packaged solutions—consistently exceeding customer expectations across diverse industries. mirepairandservices.com

Hydraulic Flanges and Components

New 120 page catalog includes popular styles of MAIN Manufacturing’s extensive offering of carbon and stainless Hydraulic Flanges and Components – ready for immediate shipment. Metric ordering information, weld specs, and dimensional information included. The “Quick Reference Guide” helps specify less popular items often stocked or quickly manufactured (generally 3-4 days) at our US plant.

MAIN Manufacturing Products, Inc.

Grand Blanc, MI

800.521.7918; FAX: 810.953.1385

E-mail: info@mainmfg.com www.mainmfg.com

Hydraulic Live Swivels Catalog

Inline and 90° hydraulic live swivels. Available in sizes from 1/8” to 2-1/2”, rated to 10,000 PSI, heat treated, superior quality alloy steel, chrome or stainless steel ball bearings, withstands heavy side loads, burnished (micro smooth) barrel bores, Viton®, Aflas®, or Teflon® encapsulated seals, zinc or nickel plated, available in 304 and 440 stainless steel, full flow - low pressure drop, rebuilding kits available.

Super Swivels

Phone: 763.784.5531

Fax: 763.784.7423

Website: www.superswivels.com

Metric & SAE

Hydraulic Tubing

Tube catalog offers comprehensive range of seamless tubing in Carbon Steel and Stainless steel.

Metric and SAE standard sizes are available, as well as CRVI-free plating on Carbon Steel tubes.

In addition, we offer Metric Copper coils and rigid tubes as well as tube clamps.

www.worldwidemetric.com sales@worldwidemetric.com 732-247-2300

Fluid Power Professionals' Day & Safety Month

By Hannah Coursey, Publisher, Fluid Power Journal

» JUNE HOLDS SPECIAL significance for those of us in the fluid power industry. It’s not just the start of summer; it’s a month dedicated to celebrating Fluid Power Professionals' Day and Fluid Power Safety Month. These dual observances give us the chance to reflect on the vital contributions of our industry while emphasizing the importance of safety in our daily work.

FLUID POWER PROFESSIONALS' MONTH RECOGNIZING EXCELLENCE

June 19 is officially recognized as Fluid Power Professionals’ Day, a day set aside to honor the engineers, technicians, mechanics, and specialists who make fluid power systems possible. This day, designated by the International Fluid Power Society (IFPS) and allied organizations in celebration of our collective efforts to innovate, maintain, and advance hydraulic and pneumatic systems that power industries worldwide.

Fluid Power is often described as a "hidden giant” (notably by John Pippenger amazing book of the same title). It’s everywhere—quietly powering machinery, vehicles, planes, ships, trains, etc.; enabling manufacturing processes; transportation, and supporting agriculture. Yet many people don’t realize

how integral it is to our modern life. Without fluid power, productivity would grind to a halt. The work done in the fluid power sphere directly impacts the world’s ability to move goods, produce food, and build infrastructure. Whether you’re designing systems or maintaining equipment, every professional in fluid power plays a critical role.

The choice of June 19 isn’t random—it’s Blaise Pascal’s birthday. Pascal, a French physicist and mathematician, laid the foundation for fluid power with his groundbreaking work in hydrodynamics and hydrostatics. Pascal’s law, states that Force is equal to Pressure times Area (F=PxA) a fundamental principle of Fluid Power. His invention of the hydraulic press revolutionized machinery and paved the way for all future innovations in fluid power.

FLUID POWER SAFETY MONTH

PRIORITIZING PROTECTION

June also coincides with National Safety Month, making it an ideal time to focus on safety in fluid power systems. Safety has always been at the forefront of our industry because hydraulic and pneumatic systems operate under extreme pressures that can pose serious risks if not handled properly.

THE IMPORTANCE OF SAFETY

Safety isn’t just about following rules—it’s about protecting lives. Fluid power systems are powerful but can be dangerous if mishandled. Risks include high-pressure leaks, injection injuries, crushing hazards from torque forces, and rapid depressurization accidents. These dangers remind us that safety protocols are non-negotiable. One of the most efficient ways to stay safe is participating in proper training and adherence to safety standards that can help to prevent accidents. Whether it’s wearing approved safety gear or conducting regular equipment inspections, every precaution matters.

STOP-DETECT-PREVENT METHOD

STOP: Isolate hazardous energy before accessing machinery.

DETECT: Identify potential risks through inspections.

PREVENT: Implement measures like monitored safety valves or proper maintenance protocols.

June is a great time for professional development. Many organizations offer training courses and seminars during this month to help professionals stay informed about emerging technologies and best practices. The IFPS provides online courses on hydraulic safety awareness, including topics like fluid injection injuries and high-risk maintenance. Courses like these are invaluable for expanding knowledge and fine-tuning expertise. They’re not just educational—they’re opportunities to improve in the fluid power sphere. See Bradley “BJ” Wagner’s article on page 14.

For Fluid Power Safety Month, it’s important to raise awareness. Whether it’s distributing safety posters or hosting toolbox talks on proper equipment handling, every effort helps create safer workplaces.

Fluid power professionals are problem-solvers who ensure that machines run smoothly and safely while driving innovation forward. Safety remains a cornerstone of everything we do. By prioritizing protection alongside progress, we ensure that our industry continues to thrive without compromising well-being.

June is more than just a month on the calendar—it’s a celebration of innovation, dedication, and responsibility within the fluid power industry. By honoring professionals and emphasizing safety practices, we strengthen the foundation of an industry that powers modern life.

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: Art@FluidPowerJournal.com www.FluidPowerJournal.com

Founders: Paul and Lisa Prass

Associate Publisher: Hannah Coursey

Editor: Lauren Schmeal

Technical Editor: Dan Helgerson, CFPAI/AJPP, CFPS, CFPECS, CFPSD, CFPMT, CFPCC

Senior Marketing Consultant: Bob McKinney

Graphic Designer: Nicholas Reeder

Accounting: Kim Kressman, Donna Bachman

Circulation Manager: Josh Shoup

INTERNATIONAL FLUID POWER SOCIETY

1930 East Marlton Pike, Suite A-2, Cherry Hill, NJ 08003-2141

Tel: 856-424-8998 • Fax: 856-424-9248

Email: AskUs@ifps.org • Web: www.ifps.org

2025 BOARD OF DIRECTORS

President: Garrett Hoisington, CFPAI, CFPS, CFPMHM

Immediate Past President: Jeff Hodges, CFPAI/AJPP, CFPMHM - Altec Industries, Inc

First Vice President: Chauntelle Baughman, CFPHSOneHydraulics, Inc.

Treasurer: Elisabeth DeBenedetto, CCFPS, GS Global Resources

Vice President Education: Daniel Fernandes, CFPS, CFPECS, Hawe Hydraulics

Vice President Membership: Brian Wheeler, CFPAI/AJPP - The Boeing Company

Vice President Certification: Bruce Bowe, CFPAI/AJPP - Altec Industries, Inc.

Vice President Marketing: Bradlee Dittmer, CFPPS - IMI Precision Engineering

DIRECTORS-AT-LARGE

Tyler Janecek, CFPHS - Engineering Systems, Inc

John Juhasz, CFPS - Kraft Fluid Systems

Stephen Blazer, CFPE- Altec Industries, Inc. Brian Kenoyer, CFPS - Cemen Tech

Jeff Curlee, CFPS -Cross Mobile Hydraulics & Controls

Quest Duperron, CFPIHM, CFPCC - Coastal Hydraulics, Inc.

Cary Boozer, CFPE - Motion Industries, Inc.

Steven Downey, CFPAI, CFPS - Hydraulex Deepak Kadamanahalli, CFPS - CNH Industrial Kyler Craig Ridgeway, CFPHS - Bradbury Company Alex Kummer, CFPE, - National Oilwell Varco Wade Lowe, CFPS - Hydraquip Distribution, Inc.

CHIEF EXECUTIVE OFFICER (EX-OFFICIO)

Donna Pollander, ACA

HONORARY DIRECTOR (EX-OFFICIO)

Ernie Parker, Hydra Tech, Inc. CFPAI/AJPP James O'Halek, CFPAI/AJPP, CFPMM, CFPMIP, CFPCCThe Boeing Company

IFPS STAFF

Chief Executive Officer: Donna Pollander, ACA

Communications Coordinator: Stephanie Coleman

Director Training/Development: Bradley (BJ) Wagner, CFPAI/ AJPP

Assistant Director: Jenna Mort

Certification Logistics Manager: Kyle Pollander

Bookkeeper: Diane McMahon

Instructional Designer & Layout: Chalie Clair

Fluid Power Journal (ISSN# 1073-7898) is the official publication

International Fluid Power Society published monthly with four supplemental issues, including a Systems Integrator Directory, Off-Highway 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 safety of unsolicited art, photographs, or manuscripts.

NEW PROBLEM Calculate the Cost of an Air Leak

By Ernie Parker, CFPAI, CFPSD, CFPS, CFPMM,

» GIVEN AN AIR compressor tank with the following dimension, how much would it cost if there was an air leak in the system that would require it to be recharged once each day for one year? The air compressor turns on at 0.55 MPa (79.75 psi) and off at 0.69 MPa (100.05 psi). The cost of air is $ 0.014/1000 normal liters ($ 0.3964/1000 SCF of air).

For the solution, see page 29.

AN OVERHEATING, CLOSED-LOOP HYDRAULIC SYSTEM

By Quest Duperron, CFPIHM, Service Manager, Coastal Hydraulics

Closed-loop hydraulic systems are known for their reliability in industrial applications that require fast directional changes and long periods of service. However, even the most dependable systems can present challenging issues which can mislead and confuse seasoned technicians. This case study details one such instance where our team was stumped for days by an overheating issue with a closed-loop hydraulic system that utilizes these components. After days of testing, analyzing schematics, speculating, and consulting industry experts, we uncovered a hidden problem that highlighted the complexities of these systems.

OVERVIEW

The system in question utilizes a Denison Gold Cup Series piston pump. In this particular configuration, the pump included 2 additional internal pumps collectively driven by a 56 kW (75-horsepower) electric motor. The primary pump produces 214 lpm (56.5gallons per minute (gpm)). The first auxiliary pump provides 31.4 lpm (8.3gpm) for the servo and replenishing system, and the second provides 46.9lpm (12.4 gpm) for the charge system. This configuration powered a Hagglunds motor which was replaced a couple of years prior as a preventative measure after being in service for almost a decade. This motor operated for 2-3 shifts daily at times operating continuously. The Hagglunds motor is not a focal point in the discussion that follows, but is specifically mentioned due to its reputation for dependability and longevity throughout the years.

A PROBLEM EMERGES

Our troubleshooting journey began when we received a call from a longtime customer experiencing an overheating issue with one of its closed-loop systems. This operationally critical system powers a conveyor belt essential for daily functions. Despite the overheating issue, the customer emphasized that the system had otherwise been running perfectly. However, the issue needed to be resolved before the summer months as this would magnify the overheating issue. Furthermore, we wanted to

ensure this was resolved early because it would lead to a shorter service life and potentially a premature catastrophic failure.

This was particularly significant to us because we had just recently installed this pump to replace the previous one a few weeks prior. The old pump had a damaged shaft seal which occurred when a coupler had been installed against the pump housing, destroying the seal’s race, and was sent out to be rebuilt. The fact that the pump was relatively new added a layer of urgency, as we wanted to prevent any permanent damage to the new pump.

INITIAL INSPECTION AND DIAGNOSIS

Upon arriving at the site, we began by verifying the temperature sensor’s readings using a handheld digital thermometer. We hoped a faulty sensor might be a simple solution; instead, this only confirmed the sensor's accuracy. As we continued investigating, we found both the inlet and outlet of the heat exchanger were cool to the touch despite the elevated system temperature. This indicated to us that the heat exchanger was not performing as intended. As a result, we immediately began to focus our attention on the heat exchanger. Our first step was to isolate the heat exchanger and verify whether oil was being supplied to it. We disconnected the heat exchanger's supply line, fed from the hot oil filter, and capped off the heat exchanger’s inlet. Then, we started the system and directed the hose over the reservoir to check for flow. We discovered that there was no oil flowing to the heat exchanger. This immediately raised our concern, prompting us to review the entire system’s plumbing against

the provided schematic speculating that, on the off chance, we may have crossed a hose somewhere during installation. However, everything appeared to be routed correctly, so we moved on. Next, we turned our attention to the hot oil filter. Though unlikely, we thought the filter might be clogged causing the fluid to never enter the heat exchanger from the pump's hot oil flushing valve (not illustrated). Once we disassembled the filter housing we discovered heavy contamination in the housing and a burst apart filter element.

Additionally, we found the filter housing’s internal 0.17 MPa (25 psi) bypass valve to be completely clogged, preventing any bypass flow. The bypass was designed for situations like this, where the element becomes too great of a restriction, obstructing flow, and allows the fluid to bypass around the element. This was an exciting discovery though tempered by the fact we did not have a replacement housing on hand which contained the internal bypass components. With that being the case, we decided

Thankfully, the flow was restored to the heat exchanger’s supply line, so we reassembled the system to begin monitoring temperatures again at the heat exchanger. With the flow returned to the heat exchanger, we began to see the inlet's temperature rise with a temperature drop across the heat exchanger. This indicated that the system was cooling again. We ultimately attributed the contamination to the previously installed pump’s time in service, determining that the issue was resolved and returned the system to its normal in-service operation.

THE OVERHEATING RETURNS

The following morning, we received an unexpected call: the overheating problem had returned. Naturally, we suspected that the filter housing was clogged again and expected to return only to replace the filter element again since the housing we needed was still on order. However, when we arrived and inspected the filter, we were surprised to find no new contamination in the filter element or housing. Confused by our findings, we

continued on page 08

repeated our earlier test by removing the hose from the hot oil filter to check for flow again. To our surprise, the flushing system was still pumping oil through the heat exchanger while the system’s temperature continued to rise. It is important to note that we only observed the temperature climbing when the pump was stroked. The system’s temperatures would remain unchanged while the pump was in the neutral position. This nuance of a clue would eventually lead us to focus on the pump’s internal operation.

DELVING DEEPER

The next day, we meticulously inspected each component of the power unit and conducted various tests; after analyzing the system's components, no obvious discrepancies were found. In our effort to be thorough, we proactively started testing some components that seemed to be unrelated to our issues, monitoring pressures and flow wherever possible ultimately unable to identify any discrepancies. Eventually, we reached out to a seasoned expert familiar with the Denison Gold Cup pumps. After sending schematics and a cumbersome explanation of our findings, we were advised to verify charge pressure and focus on the hot oil flushing valve’s operation.

With these recommendations, we verified the charge pressure 3.45 MPa (500 psi) and turned our focus to the hot oil flushing valve, which is designed to regulate oil flow to the heat exchanger from the off-service loop. After slowly backing off the valve's relief, allowing more flow into the cooling circuit, we were excited to see the temperatures starting to drop. This, however, was a short-lived victory as we soon had to abruptly stop the system when we heard the unmistakable sound of pump cavitation—a situation that could have led to serious permanent damage. Though the results were disappointing, it was this event that ultimately led us to a significant discovery: Case Pressure Replenishing, which should have prevented the pump from cavitating.

UNDERSTANDING CASE PRESSURE REPLENISHING

Case pressure replenishing, specific to these pumps, is achieved by allowing flow from the case drain circuit to enter the replenishing gallery and provide makeup flow to prevent cavitation. This is accomplished by the replenishing relief valve (8), a dual-area stepped

poppet valve that allows back flow from the case to the replenishing gallery if the case pressure exceeds the combined spring and replenishing force on top of the replenishing relief valve. To take advantage of this feature, an additional arrangement is available, which is utilized in this configuration, for systems with long lines and/or large compressible areas to provide continuous cooled flow as an additional replenishing source.

DISCOVERING THE CULPRIT

With our newfound knowledge of Case Pressure Replenishing, the next logical questions were: How were we able to achieve cavitation? Why wasn’t the case pressure supplementing the replenishing gallery’s requirements? Normally, with these conditions and using a more standardized pump, we would start to consider returning the pump for repairs or sourcing a new replacement pump. However, some key factors made us reconsider this course of action:

1. The primary pump and both auxiliary pumps were individually flow tested the day before and passed. This suggested that each pump retained its integrity and was still capable of being functional.

2. The pump’s case drain should have been continuously supplied/flushed via the D1 port, which was supplied by the heat exchanger’s discharge, exiting the case through the D2 port, ultimately flowing back to the tank. This should have provided the required make-up flow preventing cavitation.

3. The hot oil flushing valve was also supplying the motor's case flushing circuit which introduced the motor as a new factor broadening our troubleshooting focus. These factors sent us back to the drawing board, looking for another cause and questioning the cavitation condition we produced with our previous adjustments of the hot oil flushing valve. We determined that the cavitation was likely caused by a 0.159 orifice at the case flush supply (D1) which was designed to only allow 4 gpm to be re-introduced to the casing. We speculated that during our test, the hot oil flushing valve was discharging more oil than we could replace through the orifice at D1. Note: Primarily, the fluid loss should have been supplemented by the auxiliary pumps (4,5) combined 78.4 lpm (20.7gpm) flow, which should have introduced plenty of replenishment fluid through the replenishing check valves (12, 12).

After deciding that the oil flushing valve was unlikely to be the culprit, we ventured into the tank where a 0.45 MPa (65 psi) check valve was tee'd into D1, the heat exchanger outlet, and the motor's case flush supply. Our thought was that there might be issues with a worn or broken spring in the valve lowering the pressure rating, or that it might be stuck/lodged open. This would cause the replenishing circuit to drain entirely. The only issue was that the check valve was almost eight inches below the reservoir’s fluid level and not visible.

After pumping down the tank to gain sight of the valve’s discharge, noting that it was the correct valve and installed correctly, the system was started and stroked again. Immediately, we noticed that the check valve’s discharge, as well as the return filter’s discharge, was extremely heavy. This was a lucky break regarding the return filter’s discharge because it was located right next to the check valve and only visible with the lowered fluid level. After removing and inspecting the check valve, we confirmed that the valve was operating properly and unseated at 0.45 MPa (65 psi). The valve was then reinstalled, and we revisited the schematic with our new findings only to quickly realize that the most likely source of our heavy flow from both the return filter and check valve was likely supplied by the motor’s case flushing circuit. We determined that the Hagglunds motor was internally bypassing and supplying the case flushing circuit from the primary A and B circuits. While bypassing, the motor was not only generating excessive heat but also introducing the heated fluid into the pump’s case flushing circuit combating the hot oil flushing valve’s cooled fluid.

CONCLUSION

This case underscores the importance of thorough troubleshooting of closed-loop hydraulic systems, especially when dealing with intricate features including case pressure replenishing circuits. While the motor’s failure was hidden behind the functionality of the system, persistent investigation and consulting the right expertise led us to the correct diagnosis. With this conclusion, it became clear that the motor was the root cause of the heating issues, causing abnormalities in the pump. After replacing the motor, the system regained the ability to operate without the heating issues and continues to be in service to date.•

UNDERSTANDING BASIC FLUID POWER & ELECTRICAL SYMBOLS AND THEIR ANALOGIES

Graphic symbols are used to indicate the components that make up a circuit. While they do not indicate the physical layout of the components on a machine, they provide an indication of how the components interface and interact within the system. As illustrated in Fig. 1.6, hydraulic, pneumatic, and electrical systems are analogous in many ways.

Fluid power and electrical symbols and schematic diagrams are introduced throughout this study manual. The internationally recognized standard for fluid power symbology (including some associated electrical components) is ISO 1219-1 Graphical Symbols

and ISO-1219-2 Circuit Diagrams. In the United States and much of North America, the standard for electrical symbology is IEEE 315 (former ANSI Y32.2 and CSA Z99) Graphic Symbols for Electrical and Electronics Diagrams and to a lesser extent, NEMA ICS 19, Diagrams, Device Designations and Symbols. Internationally, IEC 60617 Graphical Symbols for Diagrams is the recog-nized reference. Component-level references for hydraulic, pneumatic, and electrical symbols can also be found in the Fluid Power Symbology Guide and the Fluid Power Reference Handbook, both available from the IFPS.•

TEST YOUR SKILLS

1 Graphic symbols:

a. Reference the metric system of units.

b. Show the exact location and layout of components.

c. Are a symbolic representation of the components that make up a circuit.

d. Are drawn in their actuated condition.

e. Are identical for pneumatic and hydraulic components.

See page 29 for the solution.

GENERAL RULES OF SYMBOLOGY

WORTH NOTING:

• Symbols represent functions, methods of operation, and external connections. They are not intended to show component construction, physical location, or orientation.

•  Unless noted, symbols are normally drawn in the unactuated or neutral condition.

• For complex symbols, only functional connections need be shown.

• Two or more symbols indicating a single device are typically enclosed inside a thin line.

Fig. 1.6 Fluid Power and Electrical Component Analogies

HYDRO-MECHANICAL ELECTRO-HYDRAULIC WEBINAR VS SOLUTIONS SOLUTIONS

By Lauren Schmeal, Editor, Fluid Power Journal

As presented by Dr. Medhat Khalil, Director of Professional Education at the Milwaukee School of Engineering

Dr. Khalil’s book may be found on compudraulic.com/textbooks

UNDERSTANDING THROUGH ANALOGY

FLUID POWER VS. ELECTRIC CONTROL

Iam honored to delve into the fascinating world of electrohydraulic systems. This article is based on a chapter from our professional education course, "Electrohydraulic Components and Systems," aiming to bridge the understanding between mechanical and electrical engineering perspectives.

Our goal is to facilitate a mutual understanding between professionals from mechanical and electrical engineering backgrounds through comparative analysis. By exploring the analogies between fluid power and electric control, we can appreciate the synergy that leads to advanced electrohydraulic systems. The marriage of fluid power and electric control results in electrohydraulic systems that are smarter, more compact, and more reliable.

KEY ANALOGIES

A COMPARISON

There are many analogies between fluid power and electric control systems, along with the benefits of combining them into electrohydraulic systems. In fluid power, logic functions are carried out by valves, energy conductors are pipes, and the energy medium is oil or air. In contrast, electric control utilizes relays for logic functions, wires for energy conduction, and electrons as the energy medium. Fluid power systems

commonly use pumps or compressors as energy producers, whereas electric systems employ electrical generators.

Linear actuators (cylinders) dominate fluid power, while rotational actuators (motors) are more prevalent in electric systems. While fluid power systems tend to have lower energy transmission efficiency and potential for leakage, electric systems are relatively more efficient and cleaner. Despite higher initial and running costs, fluid power excels in applications requiring high load (force or torque) or precise control. The pressure difference in fluid power is analogous to voltage in electric systems, and oil flow corresponds to electric current. Both systems exhibit power distribution patterns with sources and consumers, experiencing losses in components like pumps, valves, and conductors.

There are several parallels between components like generators/pumps, flow/pressure control vs. voltage/current control, and control valves vs. switches. It also touches on capacitive elements like accumulators/air reservoirs vs. capacitors, resistive elements like needle valves vs. resistors, and check valves vs. diodes. Hydraulic systems exhibit both linear and non-linear resistance, analogous to electrical resistance. Series and parallel arrangements of hydraulic resistances mirror electrical circuits. Finally, the piece stresses that electrohydraulic systems offer more dynamic and precise control, citing pressure control as an example, enabling adjustments on the fly and optimizing performance for varying loads and applications.

COST CONSIDERATIONS INITIAL VS. RUNNING

The initial cost of components in fluid power systems is generally higher compared

to their electric counterparts. Additionally, the running costs, including maintenance and conditioning of oil or air, can be significant. However, this doesn't imply that fluid power is inferior. There are numerous applications where fluid power excels over electric systems, particularly in situations requiring high load or precise control.

POWER DISTRIBUTION SIMILARITIES IN ENERGY FLOW

In electric systems, voltage is essential for current to flow through an electric motor, generating torque. Similarly, in fluid power systems, a pressure difference is required for flow through a hydraulic motor. This analogy highlights that pressure difference in fluid power systems is akin to voltage in electric systems, and oil flow corresponds to electric current. Both systems exhibit power distribution patterns, featuring a power source section, power control section, and a power consumer section.

ENERGY LOSSES

TRACING THE DECAY

Energy transfer from the source to the consumer involves inevitable losses. In electric systems, these losses occur in the generator armature, the motor, and through conductor leakage. Similarly, fluid power systems experience losses in the pump, valves, conductors, and actuators. It's estimated that fluid power systems can experience at least 30% losses from power generation to consumption.

SYSTEM PARALLELS A DEEPER DIVE

A closer examination reveals striking similarities between hydraulic and electric control systems:

• Power Source: Generators vs. Pumps/ Compressors

• Regulation: Flow and Pressure Control vs. Current vs. Voltage Control

• Directional Control: Control Valves vs. Switches

• Capacitive Elements: Accumulators/ Air Reservoirs vs. Capacitors (batteries for long-term energy storage)

• Resistive Elements: Needle Valves vs. Resistors

• Check Valves: Equivalent to Diodes in Electric Systems

HYDRAULIC RESISTANCE

LINEAR AND NON-LINEAR

Hydraulic systems exhibit two types of resistance:

• Orifices or Valves: These offer non-linear resistance, with a complex relationship between flow and pressure drop governed by a valve coefficient.

• Hydraulic Lines: These offer linear resistance, determined by the line's geometry and fluid properties. Electrical resistance, provided by resistors, mirrors the linear resistance in hydraulic lines.

SERIES AND PARALLEL ARRANGEMENTS

PRESSURE DROP AND RESISTANCE

When hydraulic resistances are arranged in series, the total pressure drop is the sum of individual pressure drops. Conversely, in a parallel arrangement, the total resistance is calculated using a reciprocal formula, mirroring the behavior of electrical resistances in series and parallel circuits.

CAPACITIVE ELEMENTS

ENERGY STORAGE

The accumulator in hydraulic systems, analogous to a capacitor in electric circuits, stores energy for later use in short term. The size of the accumulator, air reservoirs, or capacitor dictates the amount of energy that can be stored and the time required for charging.

POWER CALCULATION A COMMON THREAD

The formula for calculating power involves multiplying the effort variable by the flow variable. In fluid power, this translates to pressure multiplied by flow rate. Similarly, in electric power calculations, voltage is multiplied by current to determine wattage.

ELECTROHYDRAULIC SYSTEMS

A MARRIAGE OF STRENGTHS

The benefits of combining electrical and hydraulic systems are numerous. Let's consider pressure control as an example. Conventional hydraulic pressure control often involves pressure relief valves or variable displacement pumps. However, these solutions may be limiting when frequent adjustments are needed. Electrohydraulic systems offer more dynamic and precise control, enabling adjustments on the fly and optimizing performance for varying loads and applications. By integrating electronic controls with hydraulic power, we create systems that are not only efficient but also highly adaptable to complex operational requirements. This fusion marks a significant advancement, paving the way for smarter, more responsive fluid power solutions. •

June is National Safety Month

LEARN MORE WITH THE INTERNATIONAL FLUID POWER SOCIETY!

» THE IFPS IS PROUD to offer a comprehensive array of safety resources to its members. These are especially useful as our Journal observes National Safety Month this June. The National Safety Council established and currently describes the month-long event as one that focuses on safety in various areas including the workplace.

ABOUT NATIONAL SAFETY MONTH

Instituted in 1996, National Safety Month has called for the provision of free safety resources for professionals across industries, as offered by the National Safety Council. The IFPS is delighted to follow suit by offering industry-specific safety resources to its members. There is an entire webpage for fluid power professionals that is dedicated to safety within the industry at ifps.org/safety.

FREE IFPS SAFETY RESOURCES

Numerous informative safety posters are available free of charge to members. Areas of focus include eye safety, fluid injection, hose assembly, accumulators, and cylinder pressure, among others. There are bilingual posters available as well for Spanish-speaking professionals, along with free printable articles on fluid injection injuries and an IFPS-authored piece titled, “Safety is Everyone’s Responsibility.” The safety posters may be found at: https://www.ifps.org/ safety-postersak and the printable articles may be found at: https://www.ifps.org/safety

SAFETY VIDEOS

Additionally, brief yet informative informational free videos dedicated to fluid power

safety are available. Topics range from general fluid power safety to topics specific to hydraulics and pneumatics. Fluid injection injury prevention is also covered.

To view the IFPS General Fluid Power Safety Video, please access via this QR Code:

To view the IFPS Pneumatics Safety Video, please access via this QR Code:

To view the IFPS Hydraulics Safety Video, please access via this QR Code:

To view the IFPS Fluid Injection Injuries Video, please access via this QR Code:

PRINT AND VIDEO RESOURCES FOR PURCHASE

Additional in-depth resources offered for purchase include bilingual fluid injection safety cards, along with technical safety posters and various full-length courses. These detailed online training aids are geared towards, “reducing risk and eliminating hazards for workers, equipment, companies and the environment.” Fluid injection safety cards (bilingual) may be purchased at: https:// www.ifps.org/safety-cards-ak, technical safety

posters may be purchased at: https://www. ifps.org/technical-posters, and safety training courses may be purchased at: https://www. ifps.org/general-safety-courses

MEMBER WEBINARS

The IFPS also has a members-only section featuring videos and pre-recorded web seminars that are sorted and specific to safety. Other videos are specific to other industry areas but touch on safety as well. These safety-centric videos for members only may be found on the IFPS website under the Training/Resources tab, under the “Educational, Training, and Webseminar Videos (Member's Only)” section. Some topics covered include:

• General Industry Safety Guidelines

• Fluid Power Safety Guidelines

• Hydraulic Safety Guidelines

• Pneumatic Safety Guidelines

• Understanding & Preventing Fluid Injection Injuries

• Machine Safety Overview (Pneumatic Focus)

• Safety Circuits (Emerging Valve Technologies)

• Functional Safety Methods for Mobile Proportional Valve Systems

To learn more about the IFPS, visit ifps.org/about-us or email AskUs@ifps.org.

FLUID POWER PROFESSIONALS’ DAY JUNE 19 Celebrating

»THE INTERNATIONAL FLUID Power Society (IFPS) celebrates Fluid Power Professionals’ Day on June 19th to acknowledge all professionals dedicating their careers to fostering innovation and growth within the industry. Fluid power is a quiet but impactful, common force in our daily lives. Automobiles, planes, trains, and ships operate using fluid power as an indispensable component of operation. Additionally, many consumer items, from electronics to food, depend on fluid power for their very existence.

ESSENTIAL APPLICATIONS FOR MODERN FLUID POWER

From the ancient waterwheels of an emerging agrarian economy through the renaissance of industrial revolution and the automation and IT age of today, fluid power technology has advanced to improve productivity, safety, and the quality of life. This month’s issue focuses on fluid power in the medical, food processing, and plastics industries. Learn more below about its role in each field to discover more about the importance of fluid power professionals across sectors. In the medical industry, fluid power systems play a crucial role in ensuring the precision, reliability, and safety of healthcare applications. Pneumatic and hydraulic systems are used in devices inclusive of patient lifts, diagnostic equipment, and surgical tools. Pneumatics are particularly valuable in applications requiring clean, oil-free air, such as ventilators and dental instruments. Hydraulic systems provide seamless, controlled movement in equipment including hospital beds, MRI tables, and mobility aids. Additionally, fluid power enhances the functionality of rehabilitation devices and robotic surgical systems by offering responsive, precise motion control.

Fluid power systems are also essential in the food processing industry, where efficiency and sanitization are vital to operations. Pneumatic actuators and valves are used frequently due to their contamination-free operation. They’re ideal for use in tasks such as sorting, packaging, and filling. Hydraulic

systems provide the force required for heavyduty applications such as meat processing, canning, and bottling. Furthermore, fluid power enables automation in conveyor systems and robotic arms, increasing throughput and maintaining consistent product quality. Specialized components made from stainless steel and food-grade materials ensure adherence to sanitization standards.

Within the plastics industry, fluid power systems drive manufacturing such as injection molding, blow molding, and extrusion. Hydraulic systems are used in injection molding machines to generate ample pressure needed to shape plastic materials. Pneumatics deliver precise control over clamping, ejection, and material handling. Advanced fluid power technologies also contribute to energy efficiency and faster cycle times. Specific to servo-hydraulic systems, manufacturers can increase both accuracy and repeatability, ensuring high-quality product development while minimizing waste. Fluid power's durability and reliability make it indispensable in high-volume production settings.

HISTORY OF JUNE 19TH

The IFPS observes Blaise Pascal’s birthday as a day to honor all industry professionals.

Pascal was a French inventor, writer, philosopher, physicist, and mathematician, touted as the developer of the bus which served as the first mode of modern public transportation. Born over 400 years ago, the earliest stages of his career were centered on projective geometry, but Pascal ultimately focused his overarching career on science including hydrodynamics and hydrostatics. To his credit is the invention of the hydraulic press, which set the tone for future innovations. He spearheaded pneumatics experiments as well to study how air in a vacuum operates. His work validated the labor of Evangelista Torricelli, who invented the barometer and studied under Galileo.

The scientific foundation of thermodynamics and fluid power was built upon for those

who followed, largely due to Pascal and his achievements. Fluid power technology benefits the lives of so many individuals, so we dedicate this day to those whose hard work, grit, and determination benefit the greater good of society on a global scale.

WAYS TO CELEBRATE

Take the time to celebrate with your industry friends and colleagues. Here are suggestions on how to enjoy the day!

» Wear emblems, pins, badges, and shirts to help others identify your fluid power affiliation or organization.

» Treat your staff/co-workers to a pizza π. If time permits, it may be fun to plan a larger event such as an amusement park outing, picnic or company cookout. Include practical hydraulics by hosting a squirt gun battle!

» Distribute this issue of the Fluid Power Journal to your local customers and/or fluid power vendors. On June 19th, deliver goodies to those same locals.

» Go see a movie with hydraulics in action or watch a movie of your choice in a 4-D motion theater that features moving seats.

» Facilitate a scavenger hunt to detect fluid power applications you observe while out and about for fun, or during your work commute.

OPPORTUNITIES FOR FLUID POWER PHILANTHROPY

The journal encourages you to donate to help up-and-coming fluid power professionals via the Fluid Power Educational Foundation (www. fpef.org). This will fund individual scholarships for students entering into the industry.

You may also donate to the NFPA Foundation (www.nfpafoundation.org) to help the organization build more fluid power educational resources at colleges and universities. This day serves as an excellent opportunity to pay it forward and give back to an industry that has supported your career aspirations and professional growth.

June is Safety Month

IFPS IS DRIVING SAFETY FORWARD IN FLUID POWER

» JUNE IS RECOGNIZED as National Safety Month, making it the perfect time to spotlight the importance of safety in the fluid power industry. The International Fluid Power Society (IFPS) is dedicated year-round to promoting the highest safety standards to protect technicians, mechanics, engineers, and other industry professionals.

IFPS offers comprehensive safety training and resources designed to keep workers informed, prepared, and safe on the job. Developed in collaboration with industry experts, IFPS safety programs are practical, easy to understand, and focused on real-world application—ensuring professionals are equipped to create and maintain safer work environments.

In addition to training, IFPS provides valuable tools like safety cards and posters to serve as daily reminders in high-risk settings. By

fostering a strong safety culture, IFPS not only protects workers but also strengthens the overall integrity and reliability of the fluid power industry.

Make safety a priority this June—and every month. Learn more at ifps.org/safety

Fueling the Future

HOW IFPS SPONSORSHIPS SUPPORT THE FLUID POWER INDUSTRY

» AT THE HEART of innovation, education, and professional growth in fluid power, the International Fluid Power Society (IFPS) offers unique sponsorship opportunities that go beyond brand exposure—they help shape the future of the industry.

By partnering with IFPS, sponsors directly support certification programs, workforce development initiatives, educational resources, and outreach efforts that elevate industry standards. These contributions have

a lasting impact, enabling IFPS to continue promoting safety, competency, and professionalism across the field.

Sponsors can choose from flexible packages that align with their marketing goals while gaining valuable visibility through a variety of IFPS platforms—from publications and digital ads to live webinars and event recognition. Every sponsorship helps expand the reach and influence of vital resources that benefit both current and future generations of fluid power professionals.

When you sponsor IFPS, you’re not just promoting your company, you’re investing in the growth and strength of the industry. Learn more about becoming a sponsor at ifps.org/sponsorship.

Precision Meets Progress

THE NEW AND IMPROVED ECS STUDY MANUAL

» AS FLUID POWER systems grow more complex and integrated with electronic technologies, staying ahead means having the right tools to learn, adapt, and excel. The Electronic Controls Specialist (ECS) Study Manual from IFPS has been fully updated to meet the demands of today’s evolving industry.

Designed for professionals preparing for the ECS certification or those working with electronic control systems in fluid power, the revised manual offers enhanced content, clearer explanations, and updated graphics to reflect modern-day applications. Topics include sensors, PLCs, control system design, troubleshooting, and safety—presented in a format that’s both comprehensive and approachable.

Created by industry experts and backed by the International Fluid Power Society, this manual supports technicians, engineers, and specialists seeking to sharpen their skills and validate their expertise in electronic controls.

Whether you're pursuing certification or looking to strengthen your understanding of control systems, the updated ECS manual is a critical resource to guide your success. Explore the new ECS Study Manual at ifps.org/electronic-controls-specialiststudy-manual-print

Newly Certified Professionals

MARCH 2025

CONNECTOR AND CONDUCTOR (CC)

Alberto Celi Vera, Neumac S.A.

Carl Foster, Pirtek USA - Metro Detroit

ENGINEER (E)

Bishwajit Ranjan, Ellwood Texas forge Houston

HYDRAULIC SPECIALIST (HS)

Ramandeep Benipal, JEM Technical

Cody Clement, Parker Hannifin Corporation

Marcus Consoer

William Dietrich, ZF Off-Highway Solutions

Minnesota Inc.

Michael Frauendienst

Bernard Hefner, Zemarc Corp.

Aaron Indermuhle, Kraft Mobile Systems

Conor Keenan, Donald Engineering

Heidi Kloskin

Ajay Mahajan, John Deere

Tyler Merth, APSCO

Cesar Rosales Gomez, Servicios Oleohidráulicos, S.A.

Anthony Ruberti, JEM Technical

Robert Schaible, Supreme Integrated Technology

Mohaned Shahin

Scott Van Otten, Womack Machine Supply

Ryan Vaughn, The Knapheide Manufacturing Company

Todd Zieske

Bishwajit Ranjan, Ellwood Texas Forge Houston

INDUSTRIAL HYDRAULIC MECHANIC (IHM)

Ashton Bright, The Boeing Company

Duane Gray, The Boeing Company

Andrew Jensen, CMA/Flodyne/Hydradyne

William Staley, The Boeing Company

Danny Tran, The Boeing Company

MOBILE HYDRAULIC MECHANIC (MHM)

Luther Bowden, Alabama power

James Cordes

Raymond Evans, American Electric Power Co.

Matthew Fairchild, Altec

Joshua Gardenhire, Altec Industries, Inc.

Daniel Gulley, Altec Industries, Inc.

Steven Hall, ComEd

Jenaro Hernandez, ComEd

Lee Jefferson, Tacoma Public Utilities

Ryan Karas, ComEd

Robert Knittel, JR, Altec Industries, Inc.

John Lucia, ComEd

Miguel Luciano, ComEd

Tieler Osborn, Altec Industries, Inc.

Cameron Peterson, ComEd

Robert Ruiz

Anthony Tranka, Altec Industries, Inc.

Raul Zavala, AEP

PNEUMATIC SPECIALIST (PS)

Jeff Draper, Versa Products Co.

Damon Frashure, The Boeing Company

Kevin Pereira, Versa Products Co.

Paul Vandervest, IFP Automation

Deven Woolford, Versa Products Co.

Logan Zundel, Parker Hannifin Aerospace

Marcus Consoer

Heidi Kloskin

Tyler Merth, APSCO

Bishwajit Ranjan, Ellwood Texas Forge Houston

Cesar Rosales Gomez, Servicios Oleohidráulicos, S.A.

Anthony Ruberti, JEM Technical

Mohaned Shahin

SPECIALIST (S)

Richard Martindale

Michael Paulick

Thomas Zieske, SunSource

Marcus Consoer

Damon Frashure, The Boeing Company

Conor Keenan, Donald Engineering

Heidi Kloskin

Tyler Merth, APSCO

Bishwajit Ranjan, Ellwood Texas forge Houston

Cesar Rosales Gomez, Servicios Oleohidráulicos, S.A.

Anthony Ruberti, JEM Technical

Mohaned Shahin

Paul Vandervest, IFP Automation

Todd Zieske

Support Associate (SA)

Nichole Engle, Scott Industrial

Hallie Riley, IC-Fluid Power, Inc.

I TM

Digital Documents reverse-engineer systems cross/type components

Photo Navigation drilling down to individual components & parts

Interactive Prints illustrate machine operations & functions

Video Troubleshoot capture tribal knowledge & train on-the-job

Can Work Offline on any device browser

CFCINDUSTRIALTRAINING.com

7042 Fairfield Business Dr. Fairfield, OH +1 513.874.3225 info@cfcind.com

Individuals wishing to take any IFPS written certification tests can select from convenient locations across the United States and Canada. IFPS is able to offer these locations through its affiliation with the Consortium of College Testing Centers provided by National College Testing Association. Contact Kyle Pollander at Kpollander@ifps.org if you do not see a location near you. Every effort will be made to accommodate your needs.

Written Certification Test Locations

Alabama Auburn, AL Birmingham, AL Calera, AL Decatur, AL Huntsville, AL Jacksonville, AL Mobile, AL Montgomery, AL Normal, AL Tuscaloosa, AL Alaska Anchorage, AK Fairbanks, AK

Arizona Flagstaff, AZ Glendale, AZ Mesa, AZ Phoenix, AZ Prescott, AZ Scottsdale, AZ

Sierra Vista, AZ Tempe, AZ Thatcher, AZ Tucson, AZ Yuma, AZ

Arkansas Bentonville, AR Hot Springs, AR Little Rock, AR

TENTATIVE TESTING DATES FOR ALL LOCATIONS

JUNE 2025

Tuesday 6/10 • Thursday 6/26

JULY 2025

Tuesday 7/8 • Thursday 7/24

AUGUST 2025

Tuesday 8/5 • Thursday 8/21

SEPTEMBER 2025

Tuesday 9/9 • Thursday 9/25

California Aptos, CA Arcata, CA Bakersfield, CA Dixon, CA Encinitas, CA Fresno, CA Irvine, CA Marysville, CA Riverside, CA Salinas, CA San Diego, CA San Jose, CA San Luis Obispo, CA Santa Ana, CA Santa Maria, CA Santa Rosa, CA Tustin, CA Yucaipa, CA

Colorado Aurora, CO Boulder, CO Springs, CO Denver, CO

Durango, CO Ft. Collins, CO Greeley, CO Lakewood, CO Littleton, CO Pueblo, CO

Delaware Dover, DE

Georgia Albany, GA

Athens, GA

Atlanta, GA

Carrollton, GA

Columbus, GA

Dahlonega, GA

Dublin, GA

Dunwoody, GA

Forest Park, GA

Lawrenceville, GA

Morrow, GA

Oakwood, GA

Savannah, GA

Statesboro, GA

Tifton, GA

Valdosta, GA

Hawaii Laie, HI

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

Decatur, IL

Edwardsville, IL

Glen Ellyn, IL

Joliet, IL

Malta, IL

Normal, IL

Peoria, IL

Schaumburg, IL

Springfield, IL

University Park, 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

Sellersburg, IN

South Bend, IN

Terre Haute, IN

Iowa

Ames, IA

Cedar Rapids, IA

Iowa City, IA

Maryland

Arnold, MD

Bel Air, MD

College Park, MD

Frederick, MD

Hagerstown, MD

La Plata, MD

Westminster, MD

Woodlawn, MD

Wye Mills, MD

Massachusetts

Boston, MA

Bridgewater, MA

Danvers, MA

Haverhill, MA

Holyoke, MA

Shrewsbury, MA

Michigan

Ann Arbor, MI

Big Rapids, MI

Chesterfield, 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, M

Troy, MI

University Center, MI

Warren, MI

Minnesota

Alexandria, MN

Brooklyn Park, MN

Duluth, MN

Eden Prairie, MN

Granite Falls, MN

Mankato, MN

Mississippi Goodman, MS

Jackson, MS

Mississippi State, MS

Raymond, MS

University, MS

Missouri

Berkley, MO

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

New Mexico

Albuquerque, NM

Clovis, NM

Farmington, NM

Portales, NM

Santa Fe, NM

New York

Alfred, NY

Brooklyn, NY

Buffalo, NY

Garden City, NY

New York, NY

Rochester, NY

Syracuse, NY

North Carolina

Apex, NC

Asheville, NC

Boone, NC

Charlotte, NC

China Grove, NC

Durham, NC

Fayetteville, NC

Greenville, NC

Jamestown, NC

Misenheimer, NC

Mount Airy, NC

Pembroke, NC

Raleigh, NC

Wilmington, NC

North Dakota

Bismarck, ND

Ohio

Akron, OH

Cincinnati, OH

Cleveland, OH

Columbus, OH

Fairfield, OH

Findlay, OH

Kirtland, OH

Lima, OH

Maumee, OH

Newark, OH

North Royalton, OH

Rio Grande, OH

Toledo, OH

Warren, OH

Youngstown, OH

Oklahoma

Altus, OK

Bethany, OK

Edmond, OK Norman, OK

Oklahoma City, OK

Tonkawa, OK Tulsa, OK

Oregon Bend, OR Coos Bay, OR Eugene, OR Gresham, OR

Klamath Falls, OR

Medford, OR

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

Corpus Christi, TX

Dallas, TX

Denison, TX

El Paso, TX

Houston, TX

Huntsville, TX

Laredo, TX

Lubbock, TX

Lufkin, TX

Mesquite, TX

San Antonio, TX

Victoria, TX

Waxahachie, TX

Weatherford, TX

Wichita Falls, TX

Utah Cedar City, UT

Kaysville, UT

Logan, UT

Ogden, UT

Orem, UT

Salt Lake City, UT

Virginia

Daleville, VA

Fredericksburg, VA

Lynchburg, VA

Manassas, VA

Norfolk, VA

Roanoke, VA

Salem, VA

Staunton, VA

Suffolk, VA

Virginia Beach, VA

Wytheville, VA

Washington

Auburn, WA

Bellingham, WA

Bremerton, WA

Ellensburg, WA

Ephrata, WA

Olympia, WA

Pasco, WA

Rockingham, WA

Seattle, WA

Shoreline, WA

Spokane, WA

British Columbia

Abbotsford, BC

Burnaby, BC

Castlegar, BC

Delta, BC

Kamloops, BC

Nanaimo, BC

Prince George, BC Richmond, BC Surrey, BC

Vancouver, BC Victoria, BC

Manitoba Brandon, MB

Winnipeg, MB

New Brunswick

Bathurst, NB Moncton, NB

Newfoundland and Labrador

St. John’s, NL

Nova Scotia Halifax, NS

Ontario

Brockville, ON Hamilton, ON London, ON Milton, ON Mississauga, ON Niagara-on-the-Lake, ON

North Bay, ON North York, ON Ottawa, ON Toronto, ON Welland, ON Windsor, ON

Quebec

Côte Saint-Luc, QB Montreal, QB

Saskatchewan

Melfort, SK

Moose Jaw, SK

Nipawin, SK Prince Albert, SK Saskatoon, SK

Yukon Territory Whitehorse, YU

UNITED KINGDOM

Elgin, UK

GHAZNI

Kingdom of Bahrain, GHA

Thomasville, GHA

EGYPT Cairo, EG

JOB PERFORMANCE TEST LOCATIONS

Arizona California Colorado Florida Georgia

Maine Michigan Minnesota Montana New Jersey Nova Scotia Pennsylvania Texas Washington Wyoming Western Australia

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 Milton, FL

New Port Richey, FL Ocala, FL Orlando, FL

Panama City, FL

Pembroke Pines, FL

Pensacola, FL Plant City, FL

Riviera Beach, FL Sanford, FL Tallahassee, FL Tampa, FL

West Palm Beach, FL

Wildwood, FL

Winter Haven, FL

Ottumwa, IA

Sioux City, IA

Waterloo, IA

Kansas

Kansas City, KS

Lawrence, KS

Manhattan, KS

Wichita, KS

Kentucky

Ashland, KY

Bowling Green, KY

Erlanger, KY

Highland Heights, KY

Louisville, KY

Morehead, KY

Louisiana

Bossier City, LA

Lafayette, LA

Monroe, LA

Natchitoches, LA

New Orleans, LA

Shreveport, LA

Thibodaux, LA

Montana Bozeman, MT

Missoula, MT

Nebraska Lincoln, NE

North Platte, NE

Omaha, NE

Nevada Henderson, NV

Las Vegas, NV

North Las Vegas, NV

Winnemucca, NV

New Jersey

Branchburg, NJ

Cherry Hill, NJ

Lincroft, NJ

Sewell, NJ

Toms River, NJ

West Windsor, NJ

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

Wilkes-Barre, PA York, PA

South Carolina

Beaufort, SC

Charleston, SC

Columbia, SC

Conway, SC

Graniteville, SC

Greenville, SC

Greenwood, SC Orangeburg, SC

Rock Hill, SC

Spartanburg, SC

West Virginia Ona, WV

Wisconsin

La Crosse, WI Milwaukee, WI

Mukwonago, WI

Wyoming

Casper, WY

Laramie, WY

Torrington, WY

CANADA

Alberta

Calgary, AB

Edmonton, AB

Fort McMurray, AB

Lethbridge, AB

Lloydminster, AB Olds, AB Red Deer, AB

JORDAN Amman, JOR

NEW ZEALAND Taradale, NZ

CFPAI

Certified Fluid Power Accredited Instructor

CFPAJPP

Certified Fluid Power Authorized Job Performance Proctor

CFPAJPPCC

Certified Fluid Power Authorized Job Performance Proctor Connector & Conductor

CFPE

Certified Fluid Power Engineer

CFPS

Certified Fluid Power Specialist (Must Obtain CFPHS & CFPPS)

CFPHS

Certified Fluid Power Hydraulic Specialist

CFPPS

Certified Fluid Power Pneumatic Specialist

CFPECS

Certified Fluid Power

Electronic Controls Specialist

CFPMT

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

CFPIHT

Certified Fluid Power

Industrial Hydraulic Technician

CFPMHT

Certified Fluid Power

Mobile Hydraulic Technician

CFPPT

Certified Fluid Power Pneumatic Technician

CFPMM

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

CFPIHM

Certified Fluid Power

Industrial Hydraulic Mechanic

CFPMHM

Certified Fluid Power

Mobile Hydraulic Mechanic

CFPPM

Certified Fluid Power

Pneumatic Mechanic

CFPMIH

Certified Fluid Power

Master of Industrial Hydraulics

(Must Obtain CFPIHM, CFPIHT, & CFPCC)

CFPMMH

Certified Fluid Power

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

CFPMIP

Certified Fluid Power

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

CFPCC

Certified Fluid Power

Connector & Conductor

CFPSD

Fluid Power System Designer

CFPSA

Certified Fluid Power Support Associate

Tentative Certification Review Training

IFPS offers onsite review training for small groups of at least 10 persons. An IFPS accredited instructor visits your company to conduct the review. Contact kpollander@ifps.org for details of the scheduled onsite reviews listed below.

FLUID POWER SUPPORT ASSOCIATE

» CFC Industrial Training – Fairfield, Ohio | December 1–4, 2025

HYDRAULIC SPECIALIST

For custom IFPS training inquiries, please contact Bj Wagner (bwagner@ifps.org)

» CFC Industrial Training – Fairfield, Ohio | October 20–24, 2025

ELECTRONIC CONTROLS SPECIALIST

For custom IFPS training inquiries, please contact Bj Wagner (bwagner@ifps.org).

PNEUMATIC SPECIALIST

For custom IFPS training inquiries, please contact Bj Wagner (bwagner@ifps.org)

» CFC Industrial Training – Fairfield, Ohio | August 4–8, 2025

CONNECTOR & CONDUCTOR

For custom IFPS training inquiries, please contact Bj Wagner (bwagner@ifps.org).

» CFC Industrial Training – Fairfield, Ohio | July 15–17, 2025

MOBILE HYDRAULIC MECHANIC

For custom training IFPS inquiries, please contact Bj Wagner (bwagner@ifps.org)

Online Mobile Hydraulic Mechanic certification review for written test is offered through CFC Industrial Training. This course surveys the MHM Study Manual (6.5 hours) and every outcome to prepare you for the written test. Members may e-mail for a 20% coupon code off the list price. Test fees are not included.

» CFC Industrial Training – Fairfield, Ohio | June 23–27, 2025 | October 13–17, 2025

INDUSTRIAL HYDRAULIC MECHANIC

For custom IFPS training inquiries, please contact Bj Wagner (bwagner@ifps.org).

» CFC Industrial Training – Fairfield, Ohio | June 2–6, 2025

INDUSTRIAL HYDRAULIC TECHNICIAN

For custom IFPS training inquiries, please contact Bj Wagner (bwagner@ifps.org).

» For dates, call CFC Industrial Training at (513) 874-3225 or visit www.cfcindustrialtraining.com.

MOBILE HYDRAULIC TECHNICIAN

For custom IFPS training inquiries, please contact Bj Wagner (bwagner@ifps.org).

PNEUMATIC TECHNICIAN & PNEUMATIC MECHANIC

For custom IFPS training inquiries, please contact Bj Wagner (bwagner@ifps.org).

» For dates, call CFC Industrial Training at (513) 874-3225 or visit www.cfcindustrialtraining.com.

CAVITATION Valve Applications Anti-

By Robert Post, CFPHS, Consultant to Caterpillar via Actalent Services and Lauren Schmeal, Editor, Fluid Power Journal

Contamination and high temperatures are well known for causing damage to hydraulic components and systems. Fortunately, there are many articles about those topics. Cavitation is another form of contamination and is detrimental to a safe, efficient, and dependable hydraulic system. Cavitation is most often associated with the suction line connecting a reservoir to a pump but can be found in several other places within a hydraulic system including motors or double-acting cylinders. A system designer can counteract the negative effects of cavitation on those two location types by being aware of potential problem areas and taking steps to eliminate cavitation.

An Introduction to Cavitation

Cavitation occurs when the static pressure of the hydraulic fluid drops below the vapor pressure, forming small vapor-filled cavities. When those cavities implode, neighboring materials are damaged. This article focuses on avoiding cavitation in hydraulic motor or cylinder circuits. Both of those circuits will be explored individually to expand on the application of anti-cavitation check valves.

You may be wondering how anti-cavitation check valves differ from regular check valves. The answer is simple: there is no difference. Anti-cavitation check valves are valves applied in a specific manner. Check valves prevent the flow of hydraulic fluid in one direction. Consider the inversion of that idea, which is to allow flow in the other direction under the right conditions. Hydraulic motor and cylinder circuits have the same remedy with the proper application of anti-cavitation check valves to counteract induced loads from kinetic energy or the application of external forces. We will review each application of the anti-cavitation check valve individually.

Anti-Cavitation in Motors

Hydraulic motors have many applications on mobile and industrial equipment, each with unique needs. Those applications can be grouped into two basic categories: those that stop promptly when the energy input is removed, and motors that gradually coast to a stop.

Motors that depend on hydraulic power to provide torque to power winches, drive wheels, or cranes do not continue to rotate when the flow is terminated because the energy supply is removed when the valve closes. In those applications, coasting could be undesirable and may

even dictate the need for a brake to safely hold position when power is removed. Those circuits do not need anti-cavitation valves.

Alternatively, machines with a large amount of angular momentum are allowed to coast to a stop, releasing kinetic energy slowly. It may take several minutes to coast to a stop. Machines such as large fans, stump grinders, and large rotating brooms (Fig 1) require a circuit that allows fluid to flow after the directional control valve closes.

Motor spools or anti-cavitation valves allow fluid to flow after the valve returns to neutral. The first method, a motor spool in the directional control valve, (Fig 2) allows the hydraulic fluid to recirculate from the tank port to the pressure port while the valve is in neutral and the motor coasts to a stop. This is a common solution for machines with dedicated attachments, including forestry equipment with a single purpose.

A motor spool is not always installed on the host machine. Sometimes, a closed center valve is installed for compatibility with other attachments. Off-road utility machines use quick disconnects to provide a fast and easy way to replace attachments. The attachment may not always use a motor; perhaps the next attachment uses cylinders. It is common for utility vehicles, such as wheel loaders or skid steer machines, to have closed-center directional control valves to hold a cylinder in position when the valve is in neutral.

For a host machine with a closed center directional control valve, an anti-cavitation valve (Fig 3) provides a path for fluid to leave the motor while allowing make-up fluid to return to the pressure port, thus avoiding cavitation. Without the anti-cavitation check valve, closing the directional control valve abruptly stops the flow of fluid to the motor. Damage

to the motor or driveline can occur if a hydraulic motor is stopped while the inertia of any device with high kinetic energy attempts to continue to rotate to drive the motor forward until the load coasts to a stop. When that happens, the motor behaves like a pump and can generate very high pressures in the return lines. This simultaneously causes a vacuum at the pump inlet and can have potentially devastating effects. Motor cavitation is easy to detect and sounds similar to pump cavitation. Loud whining, thumping, or banging can be heard as the motor is forced to continue rotating from the kinetic energy of the spinning load. To avoid this problem, anti-cavitation check valves are installed to allow fluid leaving the outlet port to return to the inlet port. Until now, these simple examples showed a motor without a case drain. More efficient motors, e.g. a piston motor, have a case drain line that sends relatively small amounts to flow to the reservoir. When coasting to a stop, the case drain continues to send fluid out of the case drain port and must be replenished to avoid shaft seal damage. Hydraulic accumulators are commonly used (Fig 4) in such an application to replenish the fluid leaving the motor via the case drain line. Starting the motor refills the accumulator to ready it for the next shutdown. Accumulators can be large so as to provide enough fluid to accommodate case drain losses while the motor coasts to a stop, sometimes over several minutes.

4

In the earlier examples, the motors only rotate in one direction. Attempting to send flow in the reverse direction will not produce the desired performance from the motor. This is due to the fluid’s freedom to bypass the motor through the anti-cavitation check valve. For reversing motors with high energy loads, a more sophisticated circuit is required and falls beyond the scope of this introductory article. One final aspect of anti-cavitation valves to consider is valve selection and sizing.

continued on page 20

Figure 2

Figure

Figure 1 Wheel loader with broom P T

Figure 3

The valve must have a flow rating equal to or greater than the flow going to the motor. The cracking pressure must be high enough to prevent instability if elevated return pressures are present. An anti-cavitation valve with low cracking pressure can be unstable and may cause chatter or other instability.

Anti-Cavitation in Cylinders

Cylinders exposed to induced loads can also cavitate. While the formation of small vapor-filled cavities in cylinders is possible, there are elements of a cylinder that are weaker by comparison. Piston rod seals can allow air to enter the cylinder and cause aeration. Both cavitation and aeration are detrimental to a hydraulic system, so an effective countermeasure is needed.

In this example, consider the cylinder on the thumb of an excavator (Fig 5). A thumb is the additional structure, painted black in this image and used to apply force opposed to the bucket motion. The excavator's thumb is used to clamp or control a load that is larger than the bucket. At equilibrium, the bucket and thumb are applying forces to the rock in opposite directions. When clamping material with the excavator, it is common for the thumb to remain stationary while the bucket is curled toward the operator, pushing against the thumb mechanism and forcing the thumb cylinder to retract. The cylinder will withdraw safely because the pressure at the cap port is already controlled to limit

extending forces; however, conditions at the rod end are equally important.

The thumb cylinder and the external force can be represented as shown in the schematic in Fig 6. When sufficient external force is applied, a relief valve will open to safely control the cap port pressure and the piston will begin to move toward the cap end of the cylinder. Only a very small amount of piston movement is necessary to generate a vacuum at the rod port. As the piston moves toward the cap, cavitation will occur on the rod side of the piston in a tightly sealed cylinder (2 to 3 psia, or 14 to 20 kPa absolute pressure). It is more common that air is drawn into the cylinder past the rod seals which are designed to resist pressure from the inside. The internal negative pressure allows atmospheric pressure to push air into the cylinder around the rod seals or wipers. After the air has entered the rod port, it may return to the reservoir under the right conditions, or it may remain in the cylinder and cause a springy or spongey motion.

Figure 6

Cavitation in cylinders is difficult to detect because it does not have a characteristic noise like a motor. In some ways, very low cylinder pressure can cause even more damage. Contamination can be forced under rod wipers and seals, allowing water or debris to enter the cylinder. Such contamination can cause corrosion or scoring inside the cylinder or the directional control valves connected to the cylinder.

To counteract negative pressure in the rod port, anti-cavitation check valves are added to the circuit. Some directional control valves include anti-cavitation checks in the work port relief valves. When that is not the case, supplementary valves must be added. Figure 6 shows an integral anti-cavitation check on the right and a supplementary check valve on the left. The supplementary valve can be connected to a case drain or another source of make-up fluid. When low pressure is present in the rod port, cavitation is avoided because

fluid is drawn through the check valve to fill the void in the rod side of the cylinder.

Applications in Select Industries

Beyond traditional heavy-duty and industrial applications, the principles of cavitation control are critical in other sectors. Let’s explore how anti-cavitation is utilized in this issue’s focal areas, the medical, food processing, and plastics industries. In the medical industry, hydraulic systems are integral to devices such as surgical robots, imaging equipment, and patient support systems, where even minor fluid inconsistencies can jeopardize performance and patient safety. Effective anti-cavitation measures ensure these systems operate smoothly and maintain cleanliness standards for sterilization.

In food processing, hygienic and efficient fluid handling is paramount. Hydraulic components in food production lines—used in packaging, filling, and sorting—must prevent contamination that could compromise food safety. Employing anti-cavitation check valves helps maintain continuous and leakfree operation, thus reducing the risk of microbial contamination and costly cleanups while supporting compliance with rigorous sanitary standards.

Specific to plastics, particularly in processes like injection molding and extrusion, maintaining stable hydraulic pressure is essential for consistent product quality. Cavitation-induced fluctuations can lead to defects, increased cycle times, and higher scrap rates. Anti-cavitation solutions not only ensure reliable pressure control and minimize leaks, but they also contribute to improved efficiency, reduced waste, and higher-quality molded parts.

By incorporating these anti-cavitation strategies, system designers can extend the reliability and performance of hydraulic systems across diverse industries, ensuring safe, efficient, and contamination-free operations.

Conclusion

To summarize, cavitation can take place in unexpected places and cause damage in remote areas. This makes identification of the root cause difficult at times. Armed with this knowledge, system designers can anticipate cavitation problems and avoid this less familiar contamination source.•

Figure 5 Excavator with thumb

NEW PROBLEM Concrete Trucks Drum Rotation Problems

By Robert Sheaf, CFPAI/AJPP, CFPE, CFPS, CFPECS, CFPMT, CFPMIP, CFPMMH, CFPMIH, CFPMM, CFC Industrial Training

» THE DRUM ON a concrete truck rotated fine, both in clockwise and counterclockwise direction only with small loads and was limited to the projects it could be assigned to. See attached circuit.

If they exceeded about half the useable load of concrete, the drum would slow down, pulsate and stall if any more concrete was added to the mix. However, it could be rotated in the

direction that discharged the load with no problem. Both cross port reliefs were screwed all the way in for their 5,000 PSI+ setting. They did notice the charge pressure was only 25 PSI higher than the hot oil shuttle relief when in the neutral position and would drop down 30 PSI when the drum was turning.

The mechanic wasn’t that good at hydraulics but felt the drop in charge pressure

may be the problem. He increased the hot oil relief higher than the charge pressure and found nothing changed except the unit now would start to overheat. He reset the relief back to its original setting and did not know what to do next.

What would you do next?

For the solution, see page 29

Robert Sheaf has more than 45 years troubleshooting, training, and consulting in the fluid power field. Email rjsheaf@aol.com or visit his website at www.cfcindustrialtraining.com. Visit fluidpowerjournal.com/figure-it-out to view previous problems.

ELECTRIFICATION& HYBRID TRENDS

IN HEAVY CONSTRUCTION EQUIPMENT

By Rafael Cardoso, Engineering Manager, Mobile Systems and Software, Bosch Rexroth

In recent years, the construction industry has experienced a heightened desire for more sustainable solutions. Due to this, the industry is increasingly moving toward electrification of its equipment. The benefits of doing so, including greater efficiency, improved performance, quieter operation, and potential for automation, become more widely recognized. Electrification is a process that begins with the replacement of combustion engines with electric power sources, such as an electric motor powered by a battery.

Advances in battery technology have made it more feasible for the construction industry to move toward energy-efficient machines that require less maintenance. Electrification’s ability to dramatically lower carbon emissions is especially important for an industry that comprises 42% of combined global emissions. This carbon-neutral, cost-saving technology has both advantages and disadvantages. Depending on the application of each piece of equipment, different systems can be deployed, and each offers a range of benefits.

How Electrification Can Be Adopted in Construction

In construction equipment, electrification is typically relevant to drive and implement systems. Electrical components can be used for the drive system, focusing on acceleration, steering, and other functions. Electric systems are better suited for managing rotary motion, making them an excellent choice for drive systems.

Electric components can also play a role in Implement Systems, as seen in excavators where the boom, bucket, auxiliary functions, or blade are actuated using electric motors or linear actuators. Electrification in the implement system is seen as less effective and has not been widely adopted due to the historical effectiveness of hydraulics. This is particularly true for linear actuation, common in these systems especially within heavy pieces of equipment that require more energy and power density.

Smaller machines around 55 kilowatts (74 hp) or lower, e.g. compact truck loaders and

mini excavators, are more suitable candidates for full electrification due to the lower power density required for operations. Heavier machines with over 100 kilowatts (134 hp) of power pose an additional challenge for a fully electric system. Although electrical components have evolved over the years, the high power density required for operating heavy machines, such as those in the mining industry, may still impose constraints for a fully electrified solution adoption.

Benefits of Hybrid Construction Equipment

Although a variety of approaches have been attempted, manufacturers are still working to achieve energy efficiency for high-power-density machines. Today, none have proven to be the clear leader in solving the complex issues to allow for industry-wide consideration. In the meantime, hybrid applications are helping to ease the industry toward more energy-efficient solutions.

One potential approach to off-highway vehicles involves adding an electric motor to drive a hydraulic pump that controls the implement circuit. In the construction industry, hybrid solutions have been successfully applied to diverse types of off-highway machines. This is true especially when lifting loads, rollers, graders, compactors, and sweepers. Since combustion engines are only 30-40% efficient, the majority of energy created is lost through heat and noise. Conversely, electrical machines are moving the needle by reaching over 90% efficiency from battery conversion. This massively reduces the energy wasted through the process. Having said that, these efficiency advantages are not without challenges elsewhere, particularly as it pertains to machine downtime.

Compared to a combustion engine in an off-highway machine, charging the battery pack becomes an evident critical operation. Depending on the application, a battery pack can take hours to recharge. In comparison, a

combustion engine takes only a few minutes to refuel. To maximize efficiency, strategic pre-planning of the machine’s daily movements is crucial for electrified machines, ensuring optimized energy use and downtime.

Amplifying Innovation in Electrification

Software-centered, electronically controlled machines are becoming increasingly common in the construction industry. Software-focused solutions enable more innovative approaches that can be applied to off-highway machinery, such as compact track loaders, aerial work platforms, or excavators. Improving efficiency in the hydraulic portion of a hybrid machine will be critical in these digital systems. Hybrid machine efficiency can be further enhanced by optimizing electro-hydraulic systems. Multiple approaches may be used, such as allowing energy recovery during movements assisted by gravity. An example of this is when a boom actuator moves downward.

In current systems, a single pump controls multiple actuators. However, due to varying pressure requirements among actuators, energy is inevitably wasted through throttling losses, as some actuators do not require higher pressure. Several approaches have been explored to address this issue, including displacement control and multi-pressure rail systems.

Displacement control directly regulates flow from the pump while fully opening the valve spool, minimizing throttling losses. This approach can be applied even in conventional systems when only one actuator is active at a given time. Additionally, incorporating multiple pumps could enable alternative

displacement control architectures. In combination with software-centered systems, a multi-pressure rail system can reduce losses when combining the best pressure level with different actuators functioning at different pressure levels. Among various options and architectures, approaches like these are particularly relevant for battery-powered machines using hydraulic systems. They help reduce downtime and optimize battery efficiency.

Additional Industry Applications

Now, let’s explore how electrification and hybrid trends can be utilized in this month’s focal areas for the Journal: the medical, food processing, and plastics industries. Both are increasingly applicable in all three industries, offering cleaner, quieter, and more energy-efficient solutions for operating machinery such as sterilizers, conveyor systems, and injection molding equipment while reducing emissions and enhancing operational precision.

the energy efficiency of injection molding machines, extrusion systems, and recycling equipment, leading to lower operating costs and reduced environmental impact.

Connected Machines and Future Considerations

Telematics is the digital connection of heavy machines through advanced Internet of Things (IoT) capabilities. It can provide critical data to off-highway fleets, especially within electric machines. Whether a machine is preparing terrain, landscaping, or load moving, IoT and telematics systems can help determine the optimal configuration for maximum efficiency within a software-centered machine control system. The data from these actions can then be sent from the connected IoT and run through algorithms to improve efficiency.

Hybrids are becoming a viable solution for the future, whereas electrification still has room to grow before broader application.

In the medical industry, electrified equipment including imaging devices, surgical robots, and diagnostic machinery benefit from reduced noise, improved precision, and lower maintenance requirements. This is key to enhancing patient care and operational efficiency. Electrification in the food processing industry enables cleaner and more hygienic operations with reduced emissions, making it ideal for powering mixers, conveyor belts, and packaging systems in compliance with strict sanitation standards. Finally, hybrid and electric solutions in the plastics industry improve

Electrification is a promising concept, but hydraulic components are not going away anytime soon. These systems will continue to play an important role in off-highway machinery, especially for linear movements and machines with high power-density requirements. Determining the optimal system for each construction application will need to be done on a case-by-case basis. This is especially important as innovations grow in digital, software-centered machines to provide a variety of benefits for an energy-efficient operation.•

Flange End Fittings

ENHANCING HYDRAULIC SYSTEM EFFICIENCY ACROSS INDUSTRIES

By Maggie Molloy, Marketing Director at FlangeLock, and Greg Frumin, Inside Sales Manager at FlangeLock

Flange end fittings are crucial components in heavy-duty applications across various industries, ensuring the efficiency and effectiveness of hydraulic systems. They are commonly used in assemblies where space is limited, as they require less clearance surrounding the fitting when compared to other fitting varieties. Flange fittings are commonly found in construction equipment such as excavators, bulldozers, and cranes. They are also used extensively in the marine power industry, particularly in ship propulsion systems and deck machinery such as winches and cranes.

Machine Applications of Flange End Fittings

In wind turbines, flange end fittings are integral to the hydraulic pitch control systems that adjust the angle of the blades for optimal energy generation. The high-pressure hydraulic circuits in wind turbines demand fittings that can endure varying environmental conditions, including high winds and temperature extremes. Flange fittings provide the reliability needed to maintain consistent system performance, ensuring turbines can operate efficiently for extended periods with minimal downtime.

Large machine tools such as presses, milling machines, and injection molding equipment rely on hydraulic power for operation. Flange end fittings provide a secure connection for hydraulic circuits that utilize high pressure and flow rates. Their ability to minimize leaks and resist wear makes them

ideal for the continuous, high-performance demands of industrial machinery.

Challenges of Traditional Sealing Methods

Despite their widespread use in these critical applications, flange end fittings are frequently capped using inefficient, messy, and labor-intensive methods. The FlangeLock Tool is an alternative for sealing flange fittings that is quick to implement and extremely effective at preventing leaks. Sealing flange end fittings is crucial to maintaining the integrity of hydraulic systems. The introduction of contaminants into a hydraulic circuit can permanently damage the components.

One method for sealing hydraulic lines is for a technician to bolt plates onto the face of the exposed fitting, which creates a tight seal. Doing so requires tools to implement, and the task consists of several small parts. Alternatively, some operators insert rags into the open end of the fitting, which is then covered with a plastic bag; this is a quicker but highly hurried solution that allows for significant fluid leakage. This method also introduces the risk of rags being left in the lines during reassembly, which can potentially cause catastrophic damage to the machine.

The FlangeLock Solution

The FlangeLock is a hydraulic end-line cap that allows for the snug and swift sealing of open hydraulic flanges without the use of tools. FlangeLocks enable technicians to quickly seal hydraulic lines during maintenance and

repairs, reducing the time needed to service equipment. Technicians can cap off lines in seconds, streamlining repairs and allowing them to focus on the repair itself rather than managing fluid containment.

Increased speed directly translates to improved efficiency in repair operations, ensuring machinery is back in operation faster. This is critical in industries where tight project deadlines or seasonal demands require consistent equipment availability. Faster repairs naturally reduce labor costs and maintenance teams can complete tasks more smoothly, minimizing the number of labor hours required. Additionally, as FlangeLocks are simple to use and don’t require any tools, they allow for less experienced personnel to handle assembly and disassembly, further cutting labor expenses.

Hydraulic fluid is a significant expense in operating hydraulic systems, particularly for high-pressure machinery that operates using large volumes. A secure seal means that hydraulic fluid remains in the line during transport and repair versus being wasted in leakage. Over time, this can lead to substantial savings by reducing fluid replenishment frequency. In the event of a hydraulic fluid leak, discussed in further detail below, spill cleanup is essential to prevent environmental damage. Regulations often require businesses to follow labor-intensive and expensive disposal procedures. By limiting the likelihood of leaks, a FlangeLock minimizes the need for labor-intensive cleanup efforts. This saves significantly on costs and helps companies avoid potential fines for non-compliance with environmental regulations. Spill prevention is critical for a business to maintain safe working environments for staff, reducing its liability and compliance risks. Furthermore, the FlangeLock protects the hydraulic circuit from contamination. Dust, dirt, and moisture can enter open hydraulic lines during repairs, leading to compromised fluid quality. Contaminated fluid can result in system inefficiencies, increased component wear, and costly repairs and replacements. Microscopic particles account for 70% of hydraulic failures, and these enter the systems during repairs. A secure barrier at the flange end ensures that hydraulic fluid remains clean and uncontaminated during maintenance or storage. This extends the life of the hydraulic system and prevents unexpected breakdowns.

Environmental Impact of Hydraulic Fluid Leaks

Hydraulic fluid leaks pose significant environmental risks. These fluids are often petroleum-based and contain synthetic

additives, severely impacting ecosystems and public health. Hydraulic fluid leakage contributes to soil degradation, water contamination, and atmospheric pollution. Heavy machinery is frequently used in sensitive environments such as forests, wetlands, and agricultural land. Leakage in these settings can irreversibly harm the soil, making it unusable for farming or other purposes. Cleanup efforts can be complex and expensive, often requiring the treatment of large soil quantities. The introduction of these pollutants can cause a variety of harmful effects, both immediate and long-term.

Petroleum-based fluids introduce harmful hydrocarbons that are toxic to microorganisms and plant life. These hydrocarbons coat soil particles, limiting their ability to retain water and nutrients. Over time, the contaminated soil becomes infertile, inhibiting plant growth. This depreciates the agricultural value of the land and reduces the biodiversity of the area.

Another significant environmental risk associated with hydraulic fluid leakage is the contamination of water systems. Leaked fluid often gets washed into nearby bodies of water through runoff during rainfall or improper cleanup. Once hydraulic fluid enters streams, rivers, or lakes, it spreads quickly and impacts aquatic ecosystems, potentially reaching larger water networks. Once introduced to a body of water, hydraulic fluid forms a film on the water’s surface that blocks oxygen exchange while suffocating fish and other marine organisms. Toxic components of hydraulic fluid, such as heavy metals and synthetic additives, disperse through the water column and directly poison plants, animals, and microorganisms. The problem can escalate if the hydraulic fluid reaches drinking water sources, posing health risks to humans. Even trace amounts of hydraulic fluid in water can cause long-term contamination, requiring expensive filtration and treatment processes. For industries operating near major waterways, the environmental and financial costs of a hydraulic fluid spill can be immense.

Hydraulic fluids often contain volatile organic compounds (VOCs), which are released into the atmosphere during a leak. VOCs are chemical compounds prone to evaporation at room temperature. This contributes to air pollution and the formation of ground-level ozone in the area directly surrounding the leak. Ground-level ozone, a primary component of smog, is harmful to both human health and the environment. Prolonged exposure to smog can cause respiratory issues, reduce lung function, and aggravate conditions such as asthma. Increased levels of ground-level ozone can also damage crops, forests, and other vegetation.

Industry Applications

Maintaining hydraulic system integrity is essential for operational efficiency, safety, and regulatory compliance. Implementing effective sealing solutions like the FlangeLock minimizes the risks of contamination, fluid leaks, and equipment downtime. By enhancing maintenance efficiency and reducing environmental impact, the FlangeLock supports a safer and more reliable hydraulic system for a range of applications. Flange end fittings, particularly when sealed with tools like the FlangeLock, provide a reliable method to prevent fluid leaks. With quick and secure sealing, maintenance personnel can ensure minimal downtime during equipment repairs, reducing interruptions in critical procedures.

Traditional sealing methods, such as using rags or plastic covers, risk introducing fibers, dirt, or other contaminants into hydraulic lines. The FlangeLock offers a cleaner, more efficient alternative, preventing fluid leakage and ensuring that hydraulic systems remain sealed during repairs or maintenance. Additionally, using FlangeLocks helps mitigate the potential for hydraulic fluid spills, reducing the risk of costly downtime associated with sanitation procedures.

Conclusion

Flange end fittings are essential for managing high-pressure hydraulic lines that operate plastic molding machinery. By utilizing FlangeLocks, technicians can quickly seal off hydraulic lines and prevent leaks, minimizing downtime and maintaining the cleanliness of production areas. Additionally, preventing contamination through proper sealing extends the longevity of hydraulic components, reducing the risk of production delays and ensuring consistent product quality.

The FlangeLock Tool is designed for SAE Code 61, 62, & 62 CAT-Style hydraulic flanges. These hydraulic caps are constructed out of lightweight, anodized, high-tensile strength aluminum and are manufactured and assembled entirely in the United States. There is a full range of tools to cover all flange sizes, with each size color-coded for easy identification. Kits are offered in size ranges to cover different needs, and they can be ordered with or without slugs. Sizes 08 through 24 are universal for SAE Code 61, 62, & 62 CAT-Style flanges. Size 32 is available in two sizes to fit SAE Code 61 & 62 CAT-Style. Sizes 40, 48, 56, and 64 are available for code 61. •

flangelock.com

Fluid Power Industry Growth Trend

» THE LATEST DATA published by the National Fluid Power Association shows February 2025 total fluid power shipments decreased 3% from the previous month and were -14% below February 2024’s index. 3/12 and 12/12 rates of change for total fluid power, hydraulic, and pneumatic shipments are negative and trending downward. The data and charts above are from NFPA’s Confidential Shipment Statistics (CSS) program where over 70 manufacturers of fluid power products report their monthly orders and shipments. More market information is available to NFPA members, allowing them to better understand trends and anticipate change in fluid power and the many customer markets it serves. Contact NFPA at 414-778-3344 for more info.

TOTAL FLUID POWER SHIPMENTS

INDEX DATA: 3 MONTH MOVING AVERAGE & 12 MONTH MOVING AVERAGE

This graph of index data is generated by the total dollar volume reported to NFPA by CSS participants. This graph uses moving averages to smooth out the data and clearly identify trends. (Base Year 2024 = 100).

SHIPMENTS: PNEUMATIC,

MOBILE

HYDRAULIC,

AND INDUSTRIAL HYDRAULIC

INDEX DATA: 12/12 RATE OF CHANGE

Each point on this graph represents the most recent 12 months of shipments compared to the previous 12 months of shipments. For example, 7.3% (the August 2023 level of the pneumatic series) indicates that the value of pneumatic shipments from September 2022 to August 2023 were 7.3% higher than the value of pneumatic shipments from September 2021 to August 2022.

ORDERS:

PNEUMATIC, MOBILE HYDRAULIC, AND INDUSTRIAL HYDRAULIC

INDEX DATA: 12/12 RATE OF CHANGE

Each point on this graph represents the most recent 12 months of orders compared to the previous 12 months of orders. For example, 8.5% (the August 2023 level of the industrial hydraulic series) indicates that the value of industrial hydraulic orders received from September 2022 to August 2023 were 8.5% higher than the value of industrial hydraulic orders received from September 2021 to August 2022.

TOTAL SHIPMENTS: FEBRUARY 2025*

The table above shows various rates of change for the month of September 2024. Interpretation for each rate of change calculation:

- M/M %: The percent change between the current month and the previous month.

- Y/Y %: The percent change between the current month and the same month one year ago.

- 3/12 %: The percent change between the three most recent months and those same three months one year ago.

- 12/12 %: The percent change between the twelve most recent months and those same twelve months one year ago.

*Preliminary data subject to revision.

KR Media Separated Valve Line Designed for Harsh Chemical Handling

Manufactured with all-stainless steel working components, the 4BKR and new 4DKR valves are engineered to be easily mounted on a machined manifold with one inlet and multiple outlets, requiring less labor by diminishing leak points and fittings needed. Perfect for medical, chemical washing, the food industry and more, to bring reliable solutions to valve systems in various applications. Learn more about our products at www.spartanscientific.com.

Clippard Cordis Electronic Pressure Controls

Precise, linear pressure control within a closed-loop system with ultra high resolution and repeatability. The Cordis Line is a revolutionary micro-controller primed for escape velocity from a proportional control market. Built with the highest quality Clippard EVP and DVP proportional valves at its heart, the Cordis is designed to outperform the competition in every way. With unparalleled performance and flexibility not possible with current analog proportional controllers, the Cordis makes everything from calibration to sensor variety more accessible and less complicated.

customerservice@spartanscientific.com 230 McClurg Rd. Youngstown, OH 44512

Protection for All Things Hydraulic, Pneumatic and Fluid Power

MOCAP manufactures an extensive range of protective closures to guard pipes, hoses, and hydraulic fittings from dirt, moisture, and damage to help maintain equipment reliability. Included are a variety of sizes and styles of Threaded and Non-Threaded plastic Caps and Plugs for Metric, NPT, BSP, JIC and SAE Threaded Connections, Ports and Fittings. These are in addition to MOCAP’s already extensive lines of lowcost Caps, Plugs, Grips, Netting, Tubing and Tapes for general Product Protection, Finishing and Masking. All of our stocked items are ready for immediate shipment and available in Box, Mini-Pack and Micro-Pack quantities. Free Samples are always available for testing purposes.

sales@mocap.com www.mocap.com

Diamond Hydraulics Inc.

Diamond Hydraulics is a veteran owned small business that manufactures, rebuilds, and repairs hydraulic equipment including cylinders, pumps, motors, valves, power units, and much more. We were established in 1999, and have over five decades of experience in hydraulic equipment repair.

Diamond Hydraulics provides quality workmanship, extensive industry knowledge, and fast turnaround time on repairs and replacements. All repairs are brought back up to OEM standards and tested with state-of-the-art test equipment.

Diamond Hydraulics Inc.

409-986-3957 (Office) 409-986-7437 (Fax) sales@diamondhydraulicsinc.com

Inserta® Products LockstackTM D03 Isolation System replaces the labor intensive use of thread stock for D03 valve stack assemblies. The fasteners are available in ¼” increments up to 5 ½″. The Isolation Retainer engages the heads of the fasteners to prevent loosening of the stack during disassembly of the component(s) above. The system is ideal for use with horizontal stack assemblies.

Inserta® Products Blue Bell, PA www.inserta.com

IN

CUSTOMARY:

IS THE SOLUTION TO FIGURE IT OUT ON PAGE 21

The drum on a concrete truck that rotated fine in the unloading direction but not the other under load eliminated the motor and pump as the cause. If the hot oil shuttle was stuck in one position the charge pump pressure would have increased to a high noticeable amount. The solution would be to switch the motor cross port reliefs and see if the problem moved to the other port. When the first relief was remove, they found a piece of an O-ring holding the relief poppet slightly open reducing the maximum pressure of 5,000 PSI.