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We didn’t come here to go unnoticed.

If you haven’t noticed MadisonSensor before, perhaps that’s our fault. You see, we’ve been quietly designing and manufacturing the highest quality sensors and switches, initially as Madison Company, for more than 66 years. And despite operating quietly, which really isn’t a good way to do business, MadisonSensor has grown substantially over the years, along with our customers who have benefitted from our unwavering commitment to delivering on our promises.

Now that you’ve noticed us, you should also know that MadisonSensor employs a superb team of consultative design engineers who will work with you to create the optimal custom solution for your application. With years of deep industry experience, our engineers can share insights that you might not find anywhere else. And our manufacturing team can develop the most efficient way to build your finished product, saving production time and minimizing cost.

To review your application with a MadisonSensor design engineer, scan the QR code below or call 203-488-4477. You can also customize most sensors using the online configurator found on our website. And be assured that every MadisonSensor product is built to be installed with confidence.

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the technical accuracy

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.

IP67 & IP6K9K rated

Seven sizes (4-16 buttons)

Software configurable LEDs

Volume pricing starting at

The Value of Application-Based Training and How to Do It Well

By Trevor Combs, Global Technical Manager Off-Highway, Trelleborg Sealing Solutions

» TRAINING, DEVELOPMENT, CONTINUING education. However you refer to learning initiatives for your teams, it can be met with dread, apprehension, or a lack of enthusiasm from participants. However, with the right considerations and approach, effective training that goes beyond product knowledge can be invaluable for fluid power component suppliers and their customers.

When component suppliers intricately understand their customers’ applications, they can have conversations that dig deeper into finding solutions that move the needle in terms of performance, cost of ownership, and reliability. For example, when members of the Trelleborg team meet with a pump manufacturer, there are multiple opportunities to provide components and support. However, if we don’t truly understand where the pump goes, how it’s used in a bigger system, or how that system operates in each application, we can’t provide the most valuable recommendations.

Application knowledge creates opportunities for synergies and efficiencies for the customer. For these conversations to take place, your employees must be knowledgeable

beyond the products they sell. I recently developed and implemented an application-focused virtual classroom training (VCT) program at Trelleborg for our fluid power and off-highway segment and gained insightful takeaways that could help during your next internal education program.

First, there is value in extending the invitation for training to people outside of your sales team. Research and development (R&D) specialists can benefit greatly because they often work intimately on a customer project but may not be familiar with the overall application. For example, R&D team members running failure analysis can perform more thorough testing and provide unique insights if they understand the application from a broader perspective. Additionally, when people across different teams communicate during training, it can help them align on terminology. This allows everyone to speak the same language. Internal groups may use terms interchangeably or differently than the industry at large. When everyone is talking in the same room, it yields a smoother transition of information concerning future projects.

Next, consider further diversifying your training groups by including team members from countries or regions who don’t often collaborate. This broadens everyone’s knowledge base and internal network. It also adds depth to discussions. However, ensure that the training is accessible and easy to comprehend for all trainees. If there are language differences, you’ll need to break down those barriers, so everyone feels comfortable engaging. Consider using translation tools or offering communication options using online chat features.

It's best not to assume that everyone invited to the training has the product knowledge needed for an application-focused session. Make sure the audience has the right prerequisites. This can be hard to determine, but

consider the newer members of your team. It’s tempting to invite them to a deep-dive training, but if they don't have your company’s product knowledge yet, you might be doing them a disservice. Carefully considering your attendee list also helps limit class size for more manageable and focused discussions.

Using different formats for your training sessions can significantly help increase engagement. The training expectation is for participants to absorb a lot of information, so mix it up by doing whiteboard activities, group discussions, virtual polls, breakout sessions, and word clouds. Also, consider conducting the training in shorter chunks instead of all at once. We divided our VCT program into four separate sessions over two weeks. This made the information easier to digest and retain. We also created e-learning sessions for participants to complete individually before each virtual class, so we could maximize time spent together as a group.

As previously mentioned, training can be met with apprehension. Create a laid-back atmosphere that promotes participation. Allow time for icebreakers and short games, as well as opportunities for the trainees to share their knowledge and experience. Keep the mood positive and lighthearted by asking thoughtful questions throughout the training.

Application-based training for fluid power components suppliers can yield many benefits when conducted in an effective way. It generates new ideas and promotes information sharing among teams. Most importantly, it enables participants to serve their customers better as we partner to find ways to increase efficiency and improve product performance. Consider moving beyond product training and embracing how all members of the value chain can benefit when suppliers, component manufacturers, and original equipment manufacturers collaborate from a broader perspective.

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

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 of the 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 Two-Hand Safety Circut

By Ernie Parker, CFPAI, CFPSD, CFPS, CFPMM, CFPMT, CFPMIP, CFPMMH, CFPMIH, CFPE

» THE OBJECTIVE IS to have a two-hand safety circuit for which both buttons must be pushed and held to make this cylinder extend. What component is needed in the box with the question mark to make it work properly?

Note: This is not an OSHA approved safety circuit that requires both buttons to operate within .5 seconds of each other.

For the solution, see page 33.

OPTIMIZING HYDRAULIC PERFORMANCE

OVERCOMING CHALLENGES OF PRECISION FLOW MEASUREMENT

By Samantha Hannay, Marketing Manager, Titan Enterprises

Metering liquids under pressure may seem straightforward at first glance.

An example is installing a flowmeter into a product line, connecting it to an instrument, controlling the measurement with on-board software, wiring in a valve and pump, and turning on the flow system. However, real-world applications reveal a host of complexities that must be addressed to achieve precise, repeatable results to ensure accurate measurements and safe process operations. Today’s advanced process and fluid handling systems demand highly precise flow measurement. Even slight inconsistencies in system design can lead to inaccuracies, wasted product, or disrupted processes.

THE PURPOSE OF FLOWMETERS

Where hydraulic systems are concerned, flowmeters play a critical role in maintaining the integrity and effectiveness of such systems. Examples include hydraulic test rigs, calibration, confirmation of hydraulic pump outputs, and the setting and adjustment of flow control valves. Maintaining consistent process conditions, however, can be challenging. Hydraulic systems rely on the precise movement of fluid to transmit power. Any deviation from the required flow rate can lead to performance issues, excessive wear, or system failure. For instance, process conditions such as temperature fluctuations throughout the day can alter fluid viscosity and volumetric flow measurements. This impacts flow measurement accuracy. Ideally, hydraulic system designs should aim to minimize as many variables as possible within a reasonable cost. Once this foundation is established, equipment such as flow meters, pumps, and valves

can be selected to effectively compensate for any parameter variations.

DESIGN FACTORS

Flowmeters are designed to measure the rate and/or volume of fluid flowing through a hydraulic system via a variety of outputs, ranging from a simple mechanical display to full data logging. This provides real-time data on the rate of fluid movement. The information gleaned enables operators to monitor system health, detect leaks or blockages, and optimize performance. Accurate flow measurement is also crucial for maintaining consistent pressure. This helps guarantee that actuators and other components receive the correct volume of fluid, a factor that is vital for achieving the desired mechanical output. Typical hydraulic fluids include viscous oils, petroleum, or synthetic-based fluids. These are utilized due to their stability at operating temperature and for their lubricating properties. However, water-based liquids (HFA, HFB) and water Glycol Fluids (HFC) are also utilized. Increasingly biodegradable hydraulic fluids are used within hydraulic systems as well.

CRITICAL CONSIDERATIONS FOR HYDRAULIC FLUID SYSTEMS

1. System Repeatability: Hydraulic stability is essential. Air pockets in the line can lead to dynamic flow situations, causing volumetric errors in delivery. Ensuring a hydraulically locked system eliminates such variability and enhances repeatability.

2. Stable Process Conditions: Changes in pressure, temperature, or flow rate can push flowmeters into

unpredictable operational zones, affecting calibration and accuracy. Maintaining consistent conditions is vital for reliable performance.

3. Pulsating Flow Management: Selection of the pump type is important to avoid pulsating flow. Pulsation from certain pumps can disrupt flow rates, especially in aggressive chemical applications. Pressure regulators and pulsation dampers should be incorporated into flow systems to achieve a smooth and constant flow.

4. Strategic Placement of Flowmeters: Positioning the flowmeter just before the dispense valve minimizes fluid inertia and improves measurement accuracy.

5. Understanding the Impact of Viscosity on Flowmeter Accuracy: Selection of any flow measurement device should always consider the fluid viscosity, as turbine meters typically lose accuracy and performance as the fluid viscosity increases, whereas the performance, accuracy,

Industrial hydraulic system with high-pressure oval gear flowmeters

and range of positive displacement flowmeters increase with viscosity.

6. Valve Selection and Calibration: The type of shut-off valve used can impact delivery accuracy. Fast-acting solenoids are ideal for smaller pipelines, while larger setups benefit from solutions like multi-stage shut-off systems or “automatic overrun compensation” programming to fine-tune results.

7. Optimizing Electronic Flowmeters:

High-performance meters can predict stop signals in advance, ensuring consistent delivery even at high speeds.

APPLICATION EXAMPLES

In electronic control systems, integrating flowmeters with programmable logic controllers (PLCs) and digital control interfaces empowers operators with real-time diagnostics, fine-tuned setpoint adjustments, and automated alarm triggers for fault or drift detection. For example, in modern production lines, e.g., bottling beverages or manufacturing electronics, feedback from flowmeters allows for adaptive process control. Electronic systems self-correct for minute variations in flow, pressure, or temperature, which helps achieve

consistent product quality. The use of smart flowmeters with communication protocols such as Modbus, Ethernet/IP, or IO-Link further supports advanced data logging, trend analysis, and remote diagnostics. This affords maintenance teams the opportunity to preemptively address irregularities, so they don’t have an adverse impact on uptime or safety.

Within the entertainment and simulation sectors, precise flow metering is vital in hydraulic motion platforms for theme parks, ride simulators, and special effects. Sophisticated simulation environments, such as flight or vehicle simulators, rely on realtime flow and pressure data to reproduce authentic motion cues and feedback. In these industries, flowmeters linked to digital controllers can adjust actuator speeds and forces dynamically. This enhances realism and user immersion during instances such as orchestrating a complex animatronic movement or simulating the hydraulic systems of commercial aircraft. Accurate flow monitoring and electronic control integration are essential for synchronized, lifelike operation. They also help to ensure adherence to stringent safety and reliability standards that are required in public venues.

ENHANCING PROCESS EFFICIENCY

Hydraulic systems, particularly in the aerospace industry, are operating at increasingly higher pressures to achieve several key benefits, including reductions in component size, improvements in overall system efficiency, reduction of reservoir requirements’ sizes, along with decreased system weight and footprint. As operating pressures rise, the selection of an appropriate flowmeter becomes even more critical. These flowmeters need to provide accurate measurements. They also need to be capable of withstanding pressures beyond the system's maximum operating levels, incorporating a suitable safety factor to ensure long-term reliability and safety.

CONCLUSION

It is vital to account for the above factors during system design and commissioning. Its importance is also apparent when investing in the appropriate flow measurement technology that suits the application requirements. Engineers can eliminate common pitfalls in liquid metering and ensure the liquid flow system performs with precision and consistency.•

Rotary Unions & Electrical Slip Rings

the demands of sustainability and safety intensify, The Utility Expo is more vital than ever:

• Infrastructure Law & Growth: Attendees get direct insight into how new legislation and funding opportunities impact their businesses, as well as how to pivot to take advantage of emerging trends.

• Sustainability and Resilience: Focus on products and ideas driving environmental performance, grid modernization, and operational efficiency.

• Workforce Development: Education and networking underpin recruitment, retention, and upskilling, critical as the sector faces talent shortages and fast-changing job requirements.

• Safety Excellence: Programs and exhibits are dedicated to promoting bestin-class practices and technologies that safeguard workers and communities. •

SCHEDULE SNAPSHOT

From October 7-8 , the Expo will be open from 8:30 a.m . to 5:00 p.m. The final day, October 9 , the Expo will open from 8:30 a.m. to 2:00 p.m. and feature final education sessions and a wrap-up. Field classrooms and special symposia are scheduled throughout, with registration fees and pre-booking for certain sessions.

REGISTRATION AND EVENT INFO

DATES: October 7–9, 2025

VENUE: Kentucky Exposition Center, Louisville, KY. Early registration is encouraged as sessions and accommodations fill up quickly.

WEBSITE & REGISTRATION: Visit theutilityexpo.com to register, view the full agenda, secure event passes, and get updates. Follow the website and Expo communications for the latest on exhibitors, sessions, events, and travel.

RATIOMETRIC

ANALOG OUTPUTS FOR OEM PRESSURE TRANSDUCER APPLICATIONS

If you are an Original Equipment Manufacturer (OEM) looking to optimize cost and streamline installation processes, you’ll want to learn more about ratiometric (RM) output pressure transducers. These highly efficient and cost-effective solutions are engineered to accommodate a wide range of applications, such as off-highway vehicles (OHV), motorsports, and mobile hydraulic systems.

There are three key factors to consider when selecting an OEM pressure transducer: reliability, durability, and repeatability. Ratiometric output transducers incorporate all three factors and more. In this article, you will learn how these pressure measurement instruments can help you achieve cost savings while ensuring seamless integration

and enhanced performance in demanding environments.

What is Ratiometric Output?

The term "ratiometric" refers to an output signal that changes in direct proportion to a change in input or supply voltage. In other words, as the supply voltage fluctuates, the zero point and sensitivity of the output signal also vary accordingly. The concept behind this type of output is to use the same reference voltage for both the sensor and the display, such as an A/D converter. This ensures that any error in the reference voltage is automatically compensated for. Analog output signals are commonly used in pressure, temperature, and other types of sensors. When it comes to

analog output, there are various input/output (I/O) options available, including those listed in the table below.

Todd McPadden, Product Manager for OEM High-Pressure Transducers, Ashcroft

Common non-ratiometric output signals include 1-5 Vdc, 0-10 Vdc, and 4-20 mA. These types of outputs normally require minimum excitation voltages of 9 to 14 Vdc. This can be difficult to design into equipment running off typical 12 Vdc battery systems used on vehicles and other mobile equipment applications since these types of systems can be subject to voltage loss under certain conditions. For instance, environmental factors or not being charged properly can cause voltage drops on a 12 Vdc battery that can fall to 9 Vdc or below, creating supply voltage issues to operate the transducer.

Ratiometric outputs, on the other hand, require a fixed, regulated power supply source that can be low voltage and does not require internal power regulators. That makes them ideal for use on vehicle and mobile equipment applications where space and power requirements are a factor.

How Ratiometric Output Works

Ratiometric sensors typically operate on a supply voltage of 5 VDC, with a tolerance of +/- 10%. The output of the device is directly proportional to the input, ranging from 10% to 90%. To illustrate, consider a scenario where you have a 5.00 VDC supply and a pressure sensor with a range of 700 kPa (100 psi). In this case, when there is no pressure on the port (0 kPa (0 psi)), the output will be 0.5 V. Conversely, when there is full pressure on the port (700 kPa(100 psi)), the output will be 4.5 V.

Benefits of Ratiometric Transducers

As previously stated, when purchasing a pressure transducer for OEM applications, the top three features to look for include:

• Reliability - Ability to test pressure with the same tool and get a consistent reading every time. No need for a span adjustment.

• Durability - Rugged construction designed to withstand vibration, pressure spikes, and pulsation that are common in OEM applications.

• Accuracy - Technology that ensures you meet the minimum requirements of the application, such as field-proven polysilicon and thin film (CVD) pressure sensor technology.

In addition to those listed above, ratiometric transducers offer:

• Ease of design and installationRatiometric output transducers require less peripheral equipment to work in a system.

• Low-power, low-current consumption options - These sensors are able to run with lower voltage power supplies, leading to lower costs for OEM product design and increased installation value to the end-user.

• Multiple signal configurationsRatiometric sensors fit a variety of electronics options, power supplies, and PLCs.

• "Live Zero" options - This offers improved troubleshooting support, e.g., no power vs system/sensor failure.

Challenges of Ratiometric Outputs

When compared to digital or 4-20 mA outputs, which are less affected by cable length, ratiometric outputs require a fixed low-power voltage source. This means that signal loss and noise interference can occur as cable lengths increase. With that in mind, it’s best for the cable and sensor to be installed

away from noise sources such as variable frequency devices (VFD), high voltage cables, etc. Another option is for the sensors to be shielded after installation.

Examples of Ratiometric Output Transducers

Pressure sensors have offered benefits within the OEM market for more than 30 years. They’re intended for use within oil/ fuel systems, brakes, manifolds, transmission, diagnostics, and other areas. Transducers that offer ratiometric output include:

• The S1 high-volume sensor is compact and highly configurable. It offers a wide selection of material and connection choices that are designed for vibration, shock, and high cycle life.

• The G2 rugged-design sensor is engineered for installations and conditions that also produce substantial vibration, shock, and high-cycle life.

• The G3 highly compatible sensor is designed with all 316L stainless steel wetted parts for use with many types of process media and is available for low-pressure, vacuum, or absolute pressure applications.

• The KTS1 temperature sensor is designed for rugged OEM applications requiring analog outputs.

Conclusion

Each of these pressure transducers incorporates proven sensing technologies to provide a cost-effective option designed with easy installation and cost-saving benefits. This article is intended to offer readers a better understanding of ratiometric voltage output and the benefits of using these types of pressure transducers to fit various OEM needs. And, always feel free to contact us to talk to one of our industry experts and get your questions answered. The author, Todd, has more than 20 years of experience at Ashcroft. Feel free to reach out via LinkedIn or at todd. mcpadden@ashcroft.com. •

& Performance at Sea

5 Key Advantages of Hydraulic Direct Drive Systems for Marine Applications

By Collins Bioseh, Hägglunds Market Segment Manager, Marine & Offshore, Chemicals, and Renewable Energy

1. High Torque, Even at Zero to Low Speeds 2. Compactness

3. Extreme Shock Load Handling

Electromechanical components are less equipped to handle excess shock from friction. These systems tend to fail most frequently in these scenarios. Conversely, hydraulic direct drive systems are very efficient in these high-stakes circumstances. Relief systems that are in place within hydraulic drive systems allow equipment to handle the shock better due to hydraulics’ natural compressibility, where safety systems eliminate the excess pressure through relief valves to protect the system. Hydraulic fluid gives the system a natural shock absorption to increase the efficiency during higher shock loads.

4. Controllability

Similar to onshore and other industry applications, precision and control of equipment are extremely important in the marine and offshore industry. Hydraulic direct drive systems, especially those equipped with smart technology, can provide more efficient, on-demand control. Controllability can help with quick responses to commands, such as a more precise operation of joysticks and PLC controls with winches. Additionally, smart, connected hydraulics can promote efficiency in these instances. This is especially true with a closed-loop system that ensures the pump and motor are controlling flow and pressure with minimal fluid loss or heat generation.

These smart systems are equipped with sensors that can adjust pumps and valves for optimized precision. It is worth noting that these systems and other marine assets can have higher costs. Improving control via connected hydraulic direct drive systems can help keep equipment protected from any potential damage to ensure the investment is a worthwhile one. Similarly, with an increased presence of employees working in a small space with and near this large equipment, worker safety can be improved using this advanced precision to allow for controllability with fewer accidents.

5. Sustainability

The environmental impact of the machines and components used in the marine and offshore industry is constantly evolving. As previously mentioned, hydraulic direct drive systems equipped with smart control systems can improve energy efficiency through the closed-loop system, reducing waste and saving energy over time to improve and mitigate operations’ environmental impact. However, there are other ways that the drive provides sustainable solutions.

Previously, standard mineral oil was used in hydraulic applications, which has been deemed environmentally unfriendly. Now, environmentally acceptable lubricants (EALs) are utilized in hydraulic components. This means that marine and offshore workers can feel more assured that they are working with less hazardous and non-toxic materials. If hydraulic oil spills into the water, there can be significantly less harm to marine life and the entire environment.

To mitigate or eliminate oil spills, a recurring, rigorous maintenance cycle can help decrease the likelihood of occurrence, especially for instances when equipment is running constantly. When consulting system designers, operators can be proactive in helping them understand the operating cycle so they can determine the correct maintenance procedures to maintain a leak-free system.

In general, the marine climate’s intense rain, harsh seawater, strong wind, and rough sand can create significant wear and tear on equipment and components. Above-water operations must consider these marine environmental conditions to determine the frequency and type of maintenance. Alternatively, subsea vessels are submerged underwater and require a different set of maintenance procedures to eliminate spills and errors. These

are considerations system designers must think through to reduce a piece of equipment or a vessel's environmental impact. Luckily, even if there are leaks, EALs can put offshore equipment operators at ease knowing it has reduced environmental impact.

Conclusion

The marine and offshore industry stands to significantly benefit from adopting hydraulic direct drives in their operations compared to other options. This begins with a clear industry understanding of the differences in system performance, their specific impacts, and the key cost savings and benefits that new technologies bring to operations.

PRECISION CUT STAINLESS STEEL THE A d vantages OF TUBING

Precision-cut stainless steel tubing is manufactured to exact specifications using advanced cutting techniques and equipment. This process ensures that each piece of tubing has clean, smooth edges and uniform dimensions, which are crucial for maintaining tight tolerances and optimal performance in various applications. The factors that contribute to the benefits of precision-cut tubing are exact fit, enhanced reliability, optimized flow, improved aesthetics, and material efficiency. Exact fit ensures components align perfectly, reducing assembly time and effort. This precision also enhances product integrity, leading to improved performance and reliability. Enhanced reliability with precise cuts minimizes the risk of leaks or weak points, ensuring consistent

and dependable performance. Smooth interior surfaces provide optimized flow conditions for liquid or gas by reducing resistance and turbulence.

Clean, accurate cuts contribute to a professional and polished aesthetic, enhancing the visual appeal of the product. Material efficiency reduces waste by using materials more effectively, leading to cost savings and more sustainable production processes. The most important factor when cutting precision stainless steel tubing depends on the application, but in most cases, an exact fit is the top priority.

By Lisa Knowlto, Marketing Director at Eagle Stainless Tube & Fabrication Inc., with contributions from Lauren Schmeal, Editor, Fluid Power Journal

THE IMPORTANCE OF EXACT FIT

An exact fit ensures the tubing functions correctly within the assembly or device. Whether it's for medical instruments, aerospace systems, or high-performance applications, precise dimensions are critical for:

• Maintaining tight tolerances to meet engineering specifications

• Ensuring compatibility with connectors, fittings, or other components

• Preventing leaks in liquid or gas systems

• Reducing the need for rework, saving time and costs While enhanced reliability, optimized flow, improved aesthetics, and material efficiency are all valuable, they often stem from achieving an exact fit in the first place. Without it, the tubing simply won’t perform as intended. Precision-cut stainless steel tubing plays a critical role in the performance and reliability of automotive components, machine tools, and hydraulic tools. The following examples are applications for which tubing is vital to seamless operations.

APPLICATION IN ELECTRONIC CONTROLS

Modern electronic control systems frequently rely on precision-cut stainless-steel tubing as part of sensor housings, conduit runs, and cooling circuits. In high-density control cabinets or PLC enclosures, stainless steel tubing offers robust, corrosion-resistant pathways for wiring or cooling lines that must fit precisely within compact layouts. The exact fit and smooth finishes of precision-cut tubing guarantee reliable sealing when coupled with connectors or fittings, reducing the risk of leaks that could cause electrical shorts or degrade sensitive electronics. Additionally, the optimized material flow and interior cleanliness ensured by high-quality cuts support the precise operation of pneumatic or liquid-based components that may be integral to temperature regulation or actuator systems. These are hallmarks of advanced automation and control architecture.

APPLICATION IN AUTOMOTIVE COMPONENTS

Precision tubing is essential for automotive industry applications inclusive of brake lines, fuel lines, exhaust systems, and structural components. The precise fit and high dimensional accuracy of these tubes ensure leak-free connections and peak fluid flow, which are fundamental to safety and longevity. The ability to maintain tight tolerances means that precision tubing improves fuel efficiency, reduces emissions, and cuts maintenance costs, making it key to modern automobile design and manufacturing.

APPLICATION IN SIMULATION

Flight simulators, driving simulators, and advanced training devices all depend heavily on high-precision hydraulic and pneumatic actuators that translate user input into motion feedback. At the core of these motion platforms, precision-cut stainless steel tubing routes hydraulic fluid under high pressure with minimal resistance or turbulence, guaranteeing smooth actuator response and repeatable, realistic simulations. The exact fit is crucial to assembling complex, multi-axis motion systems where

misalignment could lead to performance errors or premature wear. Furthermore, the reliability and cleanliness of the tubing prevent leaks and system contamination, safeguarding both the high-value simulator hardware and the authentic user experience demanded by aviation, automotive, and defense training programs. These examples illustrate how precision-cut stainless-steel tubing directly impacts performance, safety, and efficiency in electronic controls, automotive components, and simulation environments, making it an essential engineering choice across these demanding fields.

CONCLUSION

Choose a supplier with experience and expertise to ensure precision stainless-steel tubing meets the highest standards. Whether used in medical devices, aerospace, or other critical industries, precision-cut tubing guarantees the level of quality and performance required for demanding applications. ISO-certified quality systems, including ISO 9001 and ISO 13485, help to make sure every step of the manufacturing process is carefully controlled and tracked. This means fewer defects, more reliable products, and meeting important industry standards. The result is high-quality tubing that can be consistently trusted.•

Newly Certified Professionals

JULY 2025

Moises Avila-Guzman, The Boeing Company

Raineir Casanova, The Boeing Company

Ryan Etheridge, Danfoss Power Solutions

Zane Morgan, NMC

ECS

Paul Vandervest, IFP Automation

Andy Lackman, TSE International

Brandon Shimmel, PERMCO

Jacob Rogge, Parker Hannifin

Matt Luethje, Motion

Michael Weidler, Engineered Sales Inc

Timothy Pollard

IHM

Cullen Beiler, Airline Hydraulics

Eric Davis, Airline Hydraulics

Ken McGonigle, Airline Hydraulics

Vernon Shire , RG Group

IHT

Elisha Newsome, Hydradyne LLC.

MHM

Andrew Kraus, Altec Industries, Inc.

Bryan Steigelman, Altec Industries, Inc.

Dusty Newell, Ozarks Electric

Harlan Horst, Altec Industries, Inc.

Jason Gladden, Altec Industries, Inc.

Matt France, AEP

Matthew Balon, Altec Industries, Inc.

Matthew Richards, Altec Industries, Inc.

Michael Zumbo, Florida Power and Light

Miles Wickersham, Altec Industries, Inc.

Nicholas Blockus, NCG Enterprises LLC

Richard Wideman, Altec Industries, Inc.

Robert Eickhoff, Altec Industries, Inc.

Seth Bayler, Altec Industries, Inc.

Shawn Slattery, Altec Industries, Inc.

Tony Manley, Altec Industries, Inc.

Travis Young, Nebraska Public Power District

David Ermel, NOV Hydrarig Fort Worth

Stephen Wilson, Hyspeco

Timothy Eads, Hyspeco

David Ermel, NOV Hydrarig Fort Worth

Stephen Wilson, Hyspeco

Timothy Eads, Hyspeco

Stephanie Caplinger, Hydrotech

IFPS Technical Training Programs

CUSTOM LEARNING FOR REAL-WORLD NEEDS

» THE INTERNATIONAL FLUID Power Society (IFPS) offers Fluid Power Technical Training Programs designed to meet the unique needs of companies and teams across the industry. These programs deliver targeted, practical education that supports workforce development and strengthens technical proficiency in fluid power systems.

Whether your team works with hydraulic, pneumatic, or electronic control systems, IFPS training can be tailored to meet specific equipment, applications, and knowledge levels. From hands-on workshops to classroom-style instruction, each training experience is developed and delivered by certified professionals who bring years of real-world expertise to the classroom. Companies can schedule on-site or virtual sessions to ensure training fits into their operations with minimal disruption. Topics include system components, troubleshooting techniques, safety protocols, schematic reading, and preparation for certification exams. These sessions help reduce downtime, improve safety, and enhance overall productivity.

Training through IFPS is more than education. It’s a partnership that helps employers grow stronger teams while promoting standardization, efficiency, and confidence across technical staff.

Invest in knowledge that drives performance, visit ifps.org/customtraining to learn more!

IFPS Certification Benefits for Professionals and Employers

» EARNING A CERTIFICATION through the International Fluid Power Society (IFPS) is more than a personal achievement. It is a respected validation of your technical knowledge, hands-on skill, and commitment to safety within the fluid power industry.

IFPS certification sets a standard that benefits individuals and employers alike. It demonstrates a strong foundation in fluid power systems and signals to peers, customers, and employers that you are serious about your role and professional development. For technicians, engineers, mechanics, and sales professionals, certification boosts confidence and opens doors to new opportunities.

Employers also benefit from a certified workforce. IFPS-certified professionals help reduce downtime, improve safety, support consistent troubleshooting, and maintain quality standards across operations. The result is stronger teams, increased productivity, and better customer satisfaction.

With a wide range of certification options across hydraulic, pneumatic, and electronic control systems, IFPS supports lifelong learning and technical excellence at every career stage. Study manuals, prep resources, and expert-led training options make it easier than ever to succeed.

Demonstrate your expertise and stand out in the industry. Visit ifps.org/why-get-certified-2 to explore your certification options today.

Support the Fluid Power Industry Through IFPS Sponsorship

» SPONSORING THE INTERNATIONAL

Fluid Power Society (IFPS) is more than brand exposure. It’s a way to contribute to the advancement of the fluid power industry and show support for technical education, safety, and workforce development.

IFPS sponsorship opportunities are available throughout the year and directly support the Society’s mission. From educational program development and updated training materials to certification initiatives and networking events, sponsors help make it all possible.

Sponsorship also provides valuable visibility. Your organization will be recognized in IFPS publications, email campaigns, event signage, and on the official website. Sponsors are viewed as leaders in the industry, committed to strengthening the fluid power community and supporting those who work within it.

Opportunities include sponsoring certification manuals, donating to training programs, contributing to special projects, or supporting industry events such as the Annual Meeting and Hall of Fame Ceremony. No matter the size of your company or budget, every contribution makes a difference.

Join the companies already making an impact. Visit https://ifps.org/ifpssponsorship-program to explore sponsorship options and support the future of fluid power.

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