Fluid Power Journal June 2021

JUNE 2021

fluidpowerjournal.com

MANUFACTURERS DIRECTORY

OUR LARGEST COMPANY LISTING OF THE YEAR p.25

PNEUMATICS

ESSENTIAL TO TRAIN TRAVEL CAM LOBE RADIAL PISTON MOTORS

HAPPY FLUID POWER PROFESSIONALS' DAY ON

JUNE 19th

New Heights in Load Holding for Cranes p.8 Hose-Coupling Interfaces p.11 Innovative Designs & Publishing • 3245 Freemansburg Avenue • Palmer, PA 18045-7118

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Of Quality

IN THIS ISSUE

JUNE 2021

VOLUME 28 • ISSUE 6

Features 8

Reaching New Heights in Load Holding for Cranes: Two Case Studies Careful counterbalance valve selection and smart circuit design were key.

11 Come Together: Hose-Coupling Interfaces Rigorously testing hose assembly connections pinpoints potential flaws.

22 Cam Lobe Radial Piston Motors:

Compact, Capable, Constant

8

52

The high-power, low-maintenance

technology suits multiple applications.

44 Cover Story

Riding the Rails: Pneumatics

Is Essential to Train Travel From opening doors to flushing toilets,

dynamic air technology is the ticket.

48 Test Your Skills

The Function of a Prime Mover 52 Clean Air Act: Battling Contaminants

in Pneumatic Components The right filter in the right place saves on energy and maintenance.

22

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.

CELEBRATING 60 YEARS

4 14 19 20 25 47 50 55

Notable Words IFPS Update Product Review All About Vacuum Manufacturers Directory Air Teaser Literature Review Classifieds

Our Mos t Compreh ensive Company Listing!

MAKING A DIFFERENCE

FOR YOUR BUSINESS Our cutting-edge line of hydraulic hose and fittings is not just a product division. It’s a promise of superior service, quality, technical support and availability. We’ve built our company on impeccable customer service. Let us know how we can make a difference for your business. call 800.231.7116 or email sales@texcelrubber.com

N OTA B L E WO R D S

Infuse Value Proposition into Your Company’s DNA

By Paul Johnson, President, Aggressive Hydraulics

»

IN THIS DAY and age of Amazon and Omnichannel for retail, we are becoming conditioned to buy differently while getting the best pricing available. Beyond pricing, we want the experience to be easy. You don’t have to go to the store because delivery to your home is common, and in many cases the shipping is free. Department-store chains have built multimillion-square-foot fulfillment centers to support their online shopping platforms.

If fast food is not convenient enough, you can have DoorDash deliver your meal for a modest fee. If you don’t have time to grocery shop, you can use Instacart.

How are these trends in retail affecting fluid power supply chains? Business dynamics are changing, and manufacturing suppliers, regardless of the industry, must change to adapt to customer demand for improved experience. Downward pricing pressure is always present. In some cases, the initiatives pursuant to managing a vendor’s products can tend to commoditize everything. By definition, a commodity is the market treating the good as equivalent or nearly so, with no regard to who produced it.

How do your customers view your company as part of their supply chain? Are you the supplier that provides the cheapest price? Are you viewed as a commodity? Hopefully you’re providing a value proposition that is aligned with what your customers need and want. A hydraulic component can be defined by category or class, but when your products are defined or viewed as a commodity, it is problematic. What about the company that produces it? This is when differentiation of the company and the product becomes imperative.

value proposition is much like a warranty; it is only as good as the company that stands behind it. A good value proposition should not be aspirational; it should be something ingrained in the DNA of the company culture and every employee within the organization.

Aggressive Hydraulics has embraced the tools found in the Entrepreneurial Operating System (EOS) described in the book “Traction,”

by Gino Wickman. EOS aligns our employees and focuses our efforts on the right things. For example, we have defined our Three Uniques that we believe set us apart from others in our industry. They are the heart of the value proposition our company offers to our customers.

They are unchanged by customer situations, market trends, or the economic landscape. All employees know our Three Uniques, which are part of our culture.

The company

The product or service

Companies are challenged to create a value proposition that will continue to deliver products and services that meet customer expectations in an ever-changing landscape.

Is your value proposition a reflection of your company or of your products and services? A

In addition to differentiating your company, it is also advantageous to differentiate your products or services. This has always been a challenge, but is even more important in our rapidly changing market, which is influenced by today’s retail trends and the social

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JUNE 2021

and economic impact of the pandemic. If your product is considered a commodity by the market, customers will consider price first when selecting a supplier. In contrast, a sales transaction based on value flows from collaborative discussions between supplier and customer regarding productivity, reliability, and durability. This can lead to breakthrough technology that radically changes the way work is done. It can also lead to multiple incremental changes with a greater aggregate impact than a single breakthrough technology. For the sustainability of your customer relationship, your product or service value needs to be evident and acknowledged before, during, and after the sale.

Upon inception, Aggressive Hydraulics made the conscious decision to not provide commodity products. Our hydraulic cylinders are built to order, operating on every continent, and are typically in applications supporting essential services and infrastructure. To ensure our products work as intended in demanding applications, we have a process that goes beyond custom, so we use the term purpose-built. A custom product can be a pre-engineered or predesigned product that is modified to fit an application in terms of fit, form, and function. But these products are not necessarily engineered and designed specifically for the intended application. When our sales, engineering, and manufacturing teams develop and manufacture a purpose-built product, we use another EOS tool called proven process. This is our method to consistently create successful purpose-built hydraulic cylinders for our customers, from initial gathering and understanding requirements to final delivery of the product and providing ongoing support.

Consider leveraging your internal processes, tools, and culture to provide differentiation and value selling, resulting in a positive experience for your customers and prospects.

Never lose sight of your value proposition and stand behind it. 

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3-PORT DIVERTER VALVE

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: Bob McKinney Editor: Michael Degan

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

Art Director: Quynh Fisher Eastern Region Acct Executive: Norma Abrunzo Director of Creative Services: Erica Montes Accounting: Donna Bachman, Sarah Varano

Circulation Manager: Andrea Karges

Inserta® 3-Port Diverter Valves provide a simple means to install a diverter ball valve in a circuit that uses an SAE J518 4-Bolt mounting flange pattern. Compact assemblies can be made, and adjoining components are face sealed with a leak resistant O-ring.

INTERNATIONAL FLUID POWER SOCIETY 1930 East Marlton Pike, Suite A-2, Cherry Hill, NJ 08003-2141 Tel: 856-489-8983 • Fax: 856-424-9248 Email: AskUs@ifps.org • Web: www.ifps.org

The pressure containing flange body is traceable to manufacturing and material lot. A variety of lock plates are available.

2021 BOARD OF DIRECTORS

President: Rocky Phoenix, CFPMMH - Open Loop Energy, Inc.

Immediate Past President: Jeff Kenney, CFPMHM, CFPIHM, CFPMHT - Dover Hydraulics South

First Vice President: Denis Poirier, Jr., CFPAI/AJPP, CFPHS, CFPIHM, CFPCC - Eaton Corporation

Treasurer: Jeff Hodges, CFPAI/AJPP, CFPMHM - Altec Industries, Inc. Vice President Certification: James O’Halek, CFPAI/AJPP, CFPMIP, CMPMM - The Boeing Company

Vice President Marketing: Scott Sardina, PE, CFPAI, CFPHS Waterclock Engineering

Vice President Education: Randy Bobbitt, CFPAI, CFPHS Danfoss Power Solutions

Vice President Membership: John Bibaeff, PE, CFPAI, CFPE, CFPS

INSERTA® PRODUCTS Blue Bell, PA 215.643.0192 www.inserta.com

© 2021 Inserta®

DIRECTORS-AT-LARGE Chauntelle Baughman, CFPHS - OneHydraulics, Inc. Stephen Blazer, CFPE, CFPS, CFPMHM, CFPIHT, CFPMHT Altec Industries, Inc. Randy Bobbitt, CFPAI, CFPHS - Danfoss Power Solutions Steve Bogush, CFPAI/AJPP, CFPHS, CFPIHM - Poclain Hydraulics Cary Boozer, PE, CFPE - Motion Industries, Inc. Lisa DeBenedetto, CFPS - GS Global Resources Daniel Fernandes, CFPECS, CFPS - Sun Hydraulics Brandon Gustafson, PE, CFPE, CFPS, CFPIHT, CFPMHM - Graco, Inc. Garrett Hoisington, CFPAI/AJPP, CFPS, CFPMHM Open Loop Energy Brian Kenoyer, CFPHS - Five Landis Corp.

Jon Rhodes, CFPAI, CFPS, CFPECS - CFC Industrial Training Mohaned Shahin, CFPS - Parker Hannifin Randy Smith, CFPHS - Northrop Grumman Corp.

EXECUTIVE DIRECTOR (EX-OFFICIO) Donna Pollander, ACA HONORARY DIRECTORS (EX-OFFICIO) Paul Prass, Fluid Power Journal Liz Rehfus, CFPE, CFPS Robert Sheaf, CFPAI/AJPP, CFC Industrial Training

IFPS STAFF Executive Director: Donna Pollander, ACA Communications Director: Adele Kayser Technical Director: Thomas Blansett, CFPS, CFPAI Assistant Director: Stephanie Coleman Certification Coordinator: Kyle Pollander Bookkeeper: Diane McMahon Administrative Assistant: Beth Borodziuk

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.

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JUNE 2021

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CELEBRATING 60 YEARS

HAPPY FLUID POWER PROFESSIONALS’ DAY June 19 is Fluid Power Professionals’ Day. The International Fluid Power Society designated Blaise Pascal's birthday as a day to honor all industry professionals. Past celebrations have included company picnics and barbecues, theme park outings, and pizza parties. We'll hopefully get back to those activities in 2022!

Thank you to all who’ve made the fluid power industry what it is!

www.jasonindustrial.com 630.752.0600

Industrial and Hydraulic Hose, Couplings, Equipment and Accessories where you need it, when you need it.

For the US, we have locations in Fairfield, NJ; Carol Stream, IL; Tampa, FL; Dallas, TX; Los Angeles, CA and Portland, OR.

Member of Ammega Group ammega.com ©2021 Jason Industrial

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JUNE 2021

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

PA Series

More NFPA Actuator Options Than Ever Before

TAS Series

Specification

PA Series

TA Series

Bore Range

1.50 – 4.00”

1.50 – 12.00”

Rod Diameters

One diameter per bore size

Multiple diameters per bore size

Mounting Options

12

20*

Flush Mount Option

Standard

Optional

Configurability

Basic

High

Cushioning

Auto-Cushion Standard

Adjustable & Fixed Optional

Seals

Original Ecology Seal

Bumper Piston Seal Optional

Temperature Rating

+25 – 175°F

-20 – 200°F

Steel Body Option

N/A

Available

Market Price

$

$$

FM Series

TD Series

*with TAS steel body option

Bimba’s PA Series is the perfect complement to our NFPA actuator line. It offers set bore sizes and rod diameters for a simple, straightforward counterpoint to the highly configurable TA Series. Standard designs and features provide the versatility your pneumatic applications need, at a price that can’t be beat.

Find out more www.bimba.com

TA Series

Reaching New Heights

By Steve Weber, Engineering Team, Sun Hydraulics

IN LOAD HOLDING FOR CRANES Efficient, effective load holding is not easy. But you can improve your results and achieve counterbalance in almost every application if you apply an informed counterbalance valve selection in a smart circuit design. Two case studies involving cranes demonstrate the necessity of good counterbalance valve selection and the importance of smart circuit design for the best performance and stability.

Case study 1 The Federated construction crane A load-holding challenge began with the collapse of a crane at a New York City construction site. As a result of the collapse, city building inspectors changed their inspection process at active construction projects with cranes. It would now include looking for evidence that the counterbalance valve had been adjusted after leaving the factory, which would demonstrate to the inspector that the valve had been tuned to the application. If there was no obvious way to show that there was a post-factory setting, the load-holding valve had to be replaced.

The chief engineer at Federated Crane Company contacted Sun Hydraulics and asked what options Sun could offer to help meet this new requirement.

During the discussion, the conversation expanded to include the real challenge – improving the performance of the winch on their cranes.

Federated Crane’s equipment mounts to the side of a building under construction and climbs the outside of the building as the skyscraper expands upward. A track is mounted on the building and a pony motor powers the hydraulic system that moves the crane up the side of the building. These cranes are used to deliver materials such as concrete and rebar to the floors under construction. As a result, the winch control has to account for a 1000foot payout of wire cable used to move materials up to the active floors.

Federated’s cranes had a Sun counterbalance valve installed on the winch circuit with a standard adjust screw. The engineer needed to replace the counterbalance valve with the standard adjust screw in the winch circuit with something that would satisfy the inspector’s requirement of a visible sign that the valve setting had been adjusted outside the factory.

That was the easy part. The challenge was in his request to improve the performance of the winch.

The challenge. At that time, Federated Crane was working on the reconstruction of the World Trade Center, the tallest building in the U.S. and the sixth tallest in the world. As these cranes make their way up the building, that 1000-foot payout acts like a large spring-mass-damper system but with little dampening. In a winch circuit with a counterbalance, there is an inverse relationship of a lightly loaded hook needing higher system 8

JUNE 2021

pressure to pay out. And with the long lengths of wire rope acting as a damper system, it makes stability particularly challenging.

Instability comes from the counterbalance valve being piloted too far open, which allows the actuator to overrun the pump, causing the system and pilot pressure to drop. As a result, the counterbalance valve suddenly closes. When system pressure and pilot pressure recover, the counterbalance valve reopens.

This repeating cycle of opening and closing is often called chattering and can occur in both motor and cylinder applications. Chattering is a familiar sound to hydraulics engineers working on load-holding solutions.

In the Federated Crane application, smooth acceleration and deceleration of the load was critical. Without it, the long length of wire rope acted as a spring, allowing the winch motor to briefly overrun the pump, starting that cycle of instability and chatter. Performance of the winch was at times unstable and not smooth. The company’s chief engineer reported that when the hook was lightly loaded or had no load, stability was worse than when the hook was heavily loaded.

Figure 1 shows a typical open loop motor circuit in which the counterbalance valve acts as a brake for the motor driving the winch. The Federated Crane solution was a closed loop hydrostatic motor driving the winch.

Therefore, heat generation was a prime consideration when deciding alternatives to improve performance. More heat could require more oil to be bled from the closed loop system for cooling. This might require a larger charge pump to replenish the hot oil that bleeds off for cooling.

Figure 1

The solution. This is where an informed counterbalance valve selection makes a difference. Sun recommended a load-control style counterbalance valve because it is hydraulically dampened internally and offers superior control resolution. The control resolution is improved by offering low-flow and high-flow modulation in the same valve. Additionally, it is a poppet valve, providing extremely low leakage for use as a counterbalance valve. But once the poppet leaves its seat, it acts like a spool valve to improve control resolution.

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

Pilot line dampening with an orifice is commonly included in the control circuit, which can sometimes create issues for a winch motor. A simple orifice dampens the pilot flow into the valve to slow the valve opening, but it also decreases the flow of pilot oil from the valve. This can lead to the motor overrunning the pump and cavitating. With an open loop winch motor circuit, regaining control of load might not happen, at least not until the load hits the ground, which for almost all applications is too late.

A smarter circuit design includes an orifice with a bypass check. This valve dampens the pilot flow into the valve to slow the opening, and the check valve allows the pilot flow out unrestricted to allow the counterbalance valve to close and prevent an overrunning load. Additional dampening is sometimes possible internal to the valve, making use of a similar concept to further dampen the valve opening but not slow the valve closing.

For the Federated Crane application, we combined the Sun load-control counterbalance valve with the internal dampening and pilot orifice in the new circuit with a bypass check valve and installed the resulting solution on the Federated crane. The result significantly improved stability compared to the original counterbalance valve. The chief engineer noted that the winch worked better than it ever had.

But why stop there? To further improve stability, a small accumulator was added to the pilot line. The schematic in figure 2 shows this modification on the typical open loop motor circuit. The small accumulator further smooths the pressure pulsations in the pilot resulting from the highly excitable spring-mass-damper created. The result of using an accumulator in the counterbalance pilot was, as one Sun engineer put it, “like a magic carpet ride.” After the final changes, the feedback from the Federated Crane operator was that the winch was stable in all conditions. Problem solved.

Figure 2

Case study 2 A truck-mounted crane Truck-mounted cranes offer a different set of load-holding challenges.

These machines are commonly used to deliver materials to a construction site. For this particular application, the customer already had a solution in place that was expensive, but they were experiencing long lead times. At the same time, the customer was looking for improved control resolution for safer, more precise movement of materials from the truck.

The key to this solution also included choosing the right valve and applying it in a smart circuit. Since the customer was using a balanced load-control valve, we decided to stay with that approach. With a balanced load-control valve, system pressure does not need to increase for a lightly loaded crane hook. However, the balanced load-control valve does not provide thermal relief protection. A separate relief must be built into the circuit. Even the reduced system pressure present that is used to pilot the balanced load-control valve open can still be too high, causing stability issues from an overrunning load. One way to deal with this issue is to use an orifice divider to reduce pilot pressure.

(Continued on page 10)

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JUNE 2021

9

(Continued from page 9)

The challenge. Balanced load-control valves are attractive because the inverse relationship of pilot pressure needed to open the valve, which is higher for lighter loads, is replaced by a fixed pilot pressure required to open the valve regardless of the load pressure. However, in the traditional cross-piloted application where the cylinder piston-side counterbalance is piloted off the cylinder rod side or vice versa, the pilot pressure can end up being too high. The typical schematic is shown in figure 3. This sets up the actuator for an overrunning load condition that leads to the instability. In this situation, the valve over opens, the load overruns the pump supply, the pilot pressure collapses, and the valve closes. When the pressure recovers as the pump catches up, the valve is piloted open again, and the whole cycle repeats itself.

Figure 3

The solution. The use of an orifice divider can potentially solve the issue of too much pilot pressure on a balanced load-control valve that leads to an overrunning load and instability. The orifice divider acts to reduce the pilot pressure on the valve by bleeding some pilot flow off while restricting the

Figure 4

flow into the pilot, functioning much like a voltage divider in an electrical circuit. Since the balanced load-control valve does not offer relief protection, a separate thermal relief should be added at a minimum. It is important that this relief valve is a poppet-style valve to reduce leakage on the load-holding ports. Using needle valves instead of fixed orifices can allow for tuning, but this runs the risk of allowing the effective orifice sizes to be tuned small enough that the valve closing is too slow, resulting in a cavitating actuator. However, it can be useful when prototyping. And users should consider using a bypass check on the pilot inlet orifice to allow the counterbalance valve to close as fast as it needs to. Figure 4 gives an example circuit.

Different applications may need additions to the basic load-holding circuit to stabilize the load-holding valve, as the Federated Crane application demonstrated with the long payout of wire cable. In the example of the truckmounted crane, the situation demanded a valve that can provide precise control resolution, which means adding the orifice divider to keep the pilot pressure in the range the valve requires while preventing an overrunning load condition. 

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JUNE 2021

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Hose assemblies installed in an impulse tester.

HOSE-COUPLING INTERFACES

By Matt Petti, Director of Global Product Line Management, Gates Corporation

ydraulic hose assemblies are an integral part of a hydraulic system, withstanding thousands of psi of fluid pressure, powering the articulating arms of mobile construction equipment, the hydraulic ram of a 100-ton hydraulic press, and many other heavy-duty applications. The construction of a typical hydraulic hose assembly is relatively simple – a section of rubber hose with metal couplings crimped onto both ends. What is often overlooked is the interaction between the hose and the coupling after being crimped together, referred to as the hose-coupling interface. This carefully balanced combination of a metal ferrule, rubber hose, and coupling stem (also known as a hose insert) gives a hose assembly its overall pressure rating.

Both the hose and the couplings are designed for use at a certain working pressure, so it might be assumed that when combined, the assembly’s pressure rating would match the lesser rating of the two components. But the hose-coupling interface, a critical portion of a hose assembly, can often be the limiting factor when determining a complete assembly’s working pressure. To develop a WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

dependable assembly working pressure and potential working life, there are several steps to the process. Choosing the correct ferrule, building a crimping profile and range, testing complete assemblies, including specific crimper settings, and recognizing sources of failure are all involved in the process of designing a reliable hose assembly.

To design couplings with a robust hose-coupling interface, there are variables such as the specific hose cover material, tube material, reinforcement layer thickness, and reinforcement ductility. When the ferrule component of a coupling is designed, these factors are taken into consideration and often affect the number and depth of the serrations lining the internal circumference of the ferrule.

Many manufacturers of couplings intend for these serrations to penetrate the hose’s cover material and embed themselves in its reinforcement layer, creating a stronger bond with the hose when crimped. Gates calls this a “bite-the-wire” coupling. Also, in a proper crimp, the rubber of the hose flows between the serrations as it is being crimped, further improving the connection’s strength while

minimizing intrusion from external elements.

This is why ferrule design is closely tied to the type of hose, with some coupling families offering multiple types of ferrules, depending on the hose or application.

The first step in qualifying a coupling with a hose is identifying the correct ferrule to pair with the hose. For example, even if the hose inner diameter (ID) is known, it’s possible a different ferrule will be required for an SAE 100R1 hose versus a 100R2 hose because of the differences in hose outside diameter (OD).

A cross section of the hose-coupling interface.

(Continued on page 12) JUNE 2021

11

(Continued from page 11) One-piece couplings come with a ferrule already attached, so the ferrule sizing is considered when choosing the complete coupling.

Once the correct coupling components are chosen to be qualified with a specific hose, the next step in qualification is to develop a manufacturer-provided crimp specification. This specification often refers to the final crimped OD of the coupling ferrule after it has been attached to a specific hose, measured using calipers on the flat portions across the ferrule diameter. To develop these crimp specifications, coupling development engineers estimate a target crimp OD using historical data and material property calculations.

Engineers perform initial crimps using a hydraulic crimper, with a little trial and error to get to the target crimp OD. During crimping, due to the pressure exerted by the compression of the ferrule and rubber hose, engineers expect that the coupling stem has a certain amount of bore collapse.

Using pin gauges or bore gauges (depending on the inner diameter), they take measurements to determine if there is too little collapse, resulting in a weaker clamping force between the ferrule and stem, potentially leading to coupling blowoff when pressurized. Too much collapse constricts the fluid pathway and decreases overall hydraulic system efficiency, in addition to potentially weakening the strength of the stem and leading to premature failure. Using the gauges, engineers compare the measured bore to the minimum bore allowed by SAE J516. They check the concentricity of the crimps and look for uniform crimping results around the circumference. They repeat subsequent crimping trials until they achieve an acceptable bore collapse, recording the crimp OD of the successful crimp result, which will then become the starting crimp OD for performance testing of that coupling-and-hose combination.

Testing After determining a starting crimp OD, the real fun begins. The next step in the qualification process is testing the hose assembly under pressure, running it through several tests specified by industry standards like SAE J517 and J343 to determine the assembly’s integrity. Some of these tests are to ensure customer safety, using test parameters that allow for a sufficient safety factor to accommodate spikes in system pressure when in use in the field. Other tests in SAE J517 check the assembly's performance in simulated use, testing for things like hose dimension changes, hose degradation from external sources, and potential life of assemblies.

A few tests stipulated by SAE J517 are pertinent to the hose-coupling interface: the proof test, burst test, leakage test, and finally, the impulse test. Proof testing a hose assembly is a simple test that ensures the assembly is capable 12

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of holding pressure, requiring a hydrostatic pressure of twice the working pressure, held for 30-60 seconds, and checked for leaks at the coupling and along the hose length. After passing proof testing, select assemblies are tested for burst and leakage, putting the assemblies into extreme pressure conditions to see how they perform. Burst testing requires taking the assembly to a minimum of four times the working pressure, often higher, until the assembly has catastrophic failure. Leakage testing similarly pushes the assembly to its performance limits, bringing the pressure to 70% of the minimum burst pressure, held for five minutes, removing pressure, then repressurizing to 70% of minimum burst. After advancing through this pressure cycle, engineers check the assembly for leaks or signs of failure. All three tests have binary results, either pass or fail.

The result of a coupling blowoff during testing.

crimp OD study. When they compile the data, they determine an optimum crimp OD using a statistical analysis of the best performing samples. The crimp OD they discover through this process becomes the specified crimp OD for use by hose assemblers.

Providing settings The last step for a manufacturer who offers crimpers in their product line is to make the crimping process easier for their customers by providing crimper-specific settings to reach the specified crimp OD. For example, Gates publishes crimp specifications for its hose-coupling combinations with crimpers and dies in a printed manual as well as on their eCrimp website and mobile app. While some high-volume production-grade crimpers can program a specified crimp OD into their user interface, many crimpers do not have a direct method to tie machine settings to crimp OD. When there

Blisters formed under the hose cover during testing.

The last test for hose-coupling interface evaluation is impulse testing. While impulse testing can have a binary result of whether it passes industry standard minimum impulse cycles, it is often run beyond industry minimums to test how long the hose assembly could potentially last in high-impulse cycle applications. The hose assembly, made to the proper length to allow the rated minimum bend radius, is attached to the manifold inside of an impulse tester, and the assembly is subjected to a repetitive pulsation of temperature-controlled hydraulic fluid through the hose at a frequency specified by SAE J343.

This cycling of pressure mimics the pressure changes in a hydraulic system of a customer’s machine, although at an accelerated rate. This allows the hose performance to be evaluated in a number of days in a laboratory environment as opposed to weeks or months of field testing.

During impulse testing, engineers use a range of crimp ODs above and below the starting crimp OD across several hose samples, recording the number of cycles each sample achieves before failure. When testing over a crimp range, they expect “edge failures,” where the ends are over-crimped or under-crimped, reinforcing the results of the

Cover bulge from a bad crimp.

are a variety of crimper models and die sets available, it can be an arduous task to develop crimp settings for each hose size, coupling type, die set, and crimper model. The process often begins by loading the correct die set into a crimper, determined by the closure for that specific die set. Using historical machine settings with the specific die set, engineers adjust the crimper to an estimated setting that should achieve the specified crimp OD. A series of crimp trials narrows the machine settings to hit a crimp OD within a specific tolerance above and below the specified crimp OD. The allowable tolerance varies from manufacturer to manufacturer. Engineers repeat this process for each available crimper model and record machine settings for assemblers to quickly dial in crimps during assembly production.

The effort that goes into qualifying hydraulic hose-coupling combinations ensures a reliable, high-quality hose assembly that meets performance expectations while maintaining customer safety as the highest priority. When a scientific, repeatable qualification process isn’t performed to verify a hose-coupling combination, the consequences can range from inconvenient leaking to catastrophic failure. We can attribute some failures WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

in hose assemblies to the hose, as with a pinhole burst or poor wire-reinforcement construction.

We can attribute other failures to the application, such as an over-tight bend radius or a bend near the coupling that puts increased strain on the hose-coupling interface. There are also failures specific to coupling design, such as leakage of hydraulic fluid at the termination or mechanical failure of coupling components from over-torquing the termination.

Crimp specifications shown in the Gates eCrimp app.

Interface failures Failures at the hose-coupling interface are a focus during the qualification process and can differ from the failures attributed to individual components, resulting instead from the combination of the hose and coupling. A common failure is a visible drip of hydraulic fluid exiting the coupling ferrule where it meets the hose, often resulting from a nonconcentric crimp or improper die closure. While rubber is an ideal material for hydraulic hoses because of its flexibility and durability, the integrity of the rubber in the hose-coupling interface area can degrade over time, particularly when exposed to high-temperature hydraulic fluid for hundreds of thousands (even millions!) of impulse cycles, which can also cause weeping of fluid at the hose-coupling interface over time. A more difficult failure to

diagnose is a leak caused by poor crimping in which the hydraulic fluid escapes the hose-coupling interface between the hose’s tube and cover layer, travelling down the reinforcement wire or fiber until it creates a blister in the hose cover or creates a pinhole leak. The most severe failure at the hose-coupling interface is called coupling blowoff. This often occurs from a crimp with insufficient compression and bore collapse, resulting in a loose connection of the coupling to

REMOTE CONTROL FOR HYDRAULIC APPLICATIONS

SAFE SMART STRONG

+1-305-459-0763 WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

the hose. While the crimp may appear to be satisfactory at initial pressurization, as the assembly is submitted to hundreds of thousands of impulse cycles by the hydraulic pump, the coupling in a loose crimp can separate from the hose at extremely high speeds, spraying hydraulic fluid in the process, creating a very dangerous scenario. Causes for these hose-coupling interface failures in the field are often found during lab testing, further reinforcing the importance of the qualification process.

When couplings and hoses are specifically designed to be compatible with each other, it greatly increases the chance of creating a high-quality, long-lasting, safe hose assembly.

Completing a thorough, scientific qualification process further guarantees not only the compatibility of the hose and coupling but empowers the various parties responsible for crimping hose assemblies with the necessary guidance to create repeatable, reliable crimped assemblies. Ensuring that the coupling and hose are from the same manufacturer and that crimp specifications exist for the combination from that manufacturer improves performance and reliability. The risk assumed by combining couplings and hoses that have not been qualified by their manufacturers is significant, as the possibility of failure dramatically increases and can be severe. 

www.teleradio.com

info@teleradio.com JUNE 2021

13

I F P S U P D AT E

Dear Hydraulic Specialist Test Candidate

»

I AM WRITING to let you know IFPS made some changes to the Hydraulic Specialist (HS) Study Manual. Don’t worry if you are already preparing for the test using a previous version; the updated study manual is simply streamlined. If you were unsuccessful the first time around, do not give up! You can find the streamlined study manual in your IFPS account under downloadable products.

Here are some changes to the manual: • We’ve reworded complex topics for easier comprehension, added additional examples, and enhanced graphics to support the material.

• We've streamlined the equation formulas and subsequent text describing how to compute complex formulas for ease of calculation.

• We’ve also added bar to the equations whenever pressure units are used to reflect the relevance to the fluid power industry.

Preparation is the key to a successful outcome!

IFPS wants you to succeed. There are several ways to prepare. Visit ifps.org to access these training resources: • Online HS Study Manual pretests • Recorded web seminar Outcome presentations • Use our animated circuits for a visual understanding of schematics.

• Form a study group – an excellent way to share strengths and knowledge.

CELEBRATING 60 YEARS

-

Certification Empowe rs Opportunity.

Hydraulic Specialist Certification Study M anua • Critical material to study for the Certification test • Review questions at end of each chapter • Test your knowledge with pre-test questions

l

updated

04/05/21

Respectfully,

Certification Empowers

Opportunity.

1930 E. Marlton Pike A-2, Cherry Hill, NJ 0800 P 856-424-8998 • 3 E askus@ifps.org • www.i fps.org

Thomas Blansett, CFPAI/AJPP, CFPS, CFPIHT, CFPCC IFPS Technical Director

Allegheny York AMERICA’S HYDRAULIC AND PNEUMATIC SEAL SUPPLIER 3995 N. George St. Ext. ● Manchester, PA 17345 P: 717-266-6617 ● F: 888-496-7526 ● www.AlleghenyYork.com

ENGINEERING & DESIGN

DISTRIBUTION

We offer custom engineering for sealing and part solutions that require special attention. Our engineering staff will work with you to determine what are the challenges unique to your application.

Since 1972, Allegheny York has been a recognized leader in hydraulic seal technology to meet the needs of clients in a wide range of industrial markets around the globe, including: Manufacturing, Mining, Energy Production, Construction, Agriculture, and many more…

MANUFACTURING High-volume demand Single production runs Short lead times Injection and compression molding State-of-the-art material feed system Fully tooled CNC capabilities Machining expertise Our engineers and technical team evaluate many factors: Media compatibility ● Temperature ● Pressure ● Environment ● Continuous or cyclical loads ● Static stress or dynamic conditions ● Fluid compatibility From there we decide the best material and design to recommend for your application.

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JUNE 2021

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I F P S U P D AT E

March 2021

Newly Certified Professionals MASTER MECHANIC holds IHM, MHM, PM Bradford Mailloux, The Boeing Company SYSTEM DESIGNER Tim Dimmick, National Oilwell Varco CONNECTOR & CONDUCTOR Nathanael Cochran, The Boeing Company Josef Comerford, The Boeing Company Edward Roman, The Boeing Company Daniel Shaw, The Boeing Company HYDRAULIC SPECIALIST Abdulhakime Abdurhaman Benjamin Bersie Austin Freiermuth, Force America Dave Heiderich, Flodraulic Jacek Krzciuk, Applied Industrial Technologies Harley Noll Vince Osadchuck, Parker Hannifin Michael Peterson Eric Prince Joseph Provo INDUSTRIAL HYDRAULIC MECHANIC Bradford Mailloux, The Boeing Company John Osko, The Boeing Company Mark Rippy, Coastal Hydraulics, Inc. Christopher Scime, The Boeing Company Jonathan Summers, The Boeing Company Sean Wynne, The Boeing Company MOBILE HYDRAULIC MECHANIC Ruben Briones, Altec Industries, Inc. Ryan Cappelletti, BGE Alexander Eames, Altec Industries, Inc. Evan Elderkin, BGE Ronald Farthing, Altec Industries, Inc. Noah Hill, Altec Industries, Inc. Taymen Kues, BGE Casey Leigh, Altec Industries, Inc. Christopher Pekar, Altec Industries, Inc. Jeff Roehm, Altec Industries, Inc. Norman Silon, City of Gainesville Steve Tillman, City of Gainesville Mike Williamson, Altec Industries, Inc.

WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

Precision Machining for Quality Hydraulics Contact us today 419.496.0964, ext. 203 Sales@TahomaEngineeredSolutions.com ISO 9001:2015 532 County Road 1600 • Ashland, Ohio 44805

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JUNE 2021

15

I F P S U P D AT E

June is Safety Month »

SAFETY IS EVERYONE’S responsibility. Take the responsibility to improve safety standards whenever an opportunity presents itself.

Did you know there are general safety guidelines for all fluid power technologies in every certification study manual?

IFPS mails Fluid Injection Safety Cards free to every new member. The cards contain five critical pieces of information for doctors and emergency medical technicians treating fluid injection injuries. IFPS also offers safety posters containing the same critical information.

Think BIG, or small.

CELEBRATING 60 YEARS

SAFETY FOCUS

FAST RESPONSE FOR INJECTION INJURIES Injection injuries can result in ampu tation or death.

DO NOT DELAY - Fast treatment is essential.

SEEK IMMEDIATE MEDICAL ASSIS

TANCE HERE

1. WHAT TYPE OF FLUID?

CRITICAL PIECES OF INFORMATION FOR DOCTORS

Grease, oils and hydraulic fluid often don’t cause any initial reaction, paint and paint thinners/solvents dissolve fat and will cause early, intense inflammatory reactions.

2. WHAT IS THE AMOUNT OF FLUID

INJECTED?

The more fluid injected, the less room for 3. WHAT WAS THE PRESSURE OF FLUID

blood circulation.

INJECTED?

Pressure of the fluid may help determin e the amount injected.

4. WHAT IS THE DEGREE OF SPREAD

OF INJECTED MATERIAL?

Location of the injury will help determine the degree of spread. Cases have been reported where fluid injected into the hand has been recovered as far away as the elbow.

5. HOW MUCH TIME LAPSED BETWEEN

UPDATED up to 50-axis

INJECTION AND TREATMENT?

This is an extremely important factor determin ing the outcome. The sooner that surgery is carried out post-inje ction, the less long-term disability will result.

The information expressed above is not medical advice or a substitute for a professional medical opinion.

IFPS does not assume any liability The International Fluid Power Society that may arise from its use or nonuse.

(IFPS) provides this information IFPS does not verify that this information for your convenience, and is valid, current, or suitable for any situation. Consult a medical professional in the event of an emergency. immediately

NEW up to 18-axis

RMC200 Standard

RMC200 Lite

One axis or fifty; position, velocity, force,

SAFETY FOCUS

or position-pressure/force, look to Delta RMC Motion Controllers and graphical

FAST RESPONSE FOR INJECTION INJURIES Injection injuries can result in amputation or death.

DO NOT DELAY - Fast treatment is essential.

SEEK IMMEDIATE MEDICAL ASSISTANCE HERE

RMCTools software to make complex motion easier, smoother, and more precise.

Fast, precise, elegant, servo-hydraulic control Big or small, get your next project running more quickly than you thought possible.

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COMPUTER SYSTEMS RMC75 1 or 2-axis

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RMC200 up to 32 50-axis

RMC150 up to 8-axis

Motion Control

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20171.DELTA_AD_4.75x7.75.indd 1

Online Hydraulic Safety Awareness Training In conjunction with the International Hydraulics Safety Authority, IFPS offers online hydraulic safety awareness training courses.

IFPS offers four online hydraulic safety awareness training courses: • Fluid Injection Awareness • Exposure • High-Risk Maintenance Level • Hydraulic Safety in Construction The International Hydraulics Safety Authority, recognized internationally, is the leader in hydraulic safety awareness training and develops the most comprehensive training curriculum available in the safety industry.

To order safety cards, safety posters, and safety courses, visit www.ifps.org/Training Resources.

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

1/25/21 7:46 PM

I F P S U P D AT E

AVAILABLE IFPS CERTIFICATIONS 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 CFPMEC (In Development) Mobile Electronic Controls CFPIEC (In Development) Industrial Electronic Controls

WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

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.

HYDRAULIC SPECIALIST CERTIFICATION REVIEW September 13-16, 2021 - Fairfield, OH - CFC Industrial Training | Written test: September 16, 2021 September 27-30, 2021 - Milwaukee, WI, MSOE | Written test: September 30, 2021 PNEUMATIC SPECIALIST July 27-29, 2021 - Fairfield, OH - CFC Industrial Training | Written test: July 29, 2021 ELECTRONIC CONTROLS CERTIFICATION REVIEW August 9-12, 2021 - Fairfield, OH - CFC Industrial Training | Written test: August 12, 2021 CONNECTOR & CONDUCTOR CERTIFICATION REVIEW November 16-17, 2021 - Fairfield, OH - CFC Industrial Training | Written and JP test: November 18, 2021 MOBILE HYDRAULIC MECHANIC CERTIFICATION REVIEW Online Mobile Hydraulic Mechanic Certification Review (for written test) offered through info@cfcindustrialtraining.com. This course takes you through all chapters of the MHM Study Manual (6.5 hours) and every outcome to prepare you for the written MHM test. Members receive 20% off.

(Test fees are additional - separate registration required.)

August 30 - September 1, 2021 - Fairfield, OH - CFC Industrial Training | Written and JP test: September 2, 2021

INDUSTRIAL HYDRAULIC MECHANIC CERTIFICATION Call for dates. Phone: 513-874-3225 - CFC Industrial Training, Fairfield, Ohio

INDUSTRIAL HYDRAULIC TECHNICIAN CERTIFICATION REVIEW TRAINING Call for dates. Phone: 513-874-3225 - CFC Industrial Training, Fairfield, Ohio

MOBILE HYDRAULIC TECHNICIAN CERTIFICATION REVIEW TRAINING Call for dates. Phone: 513-874-3225 - CFC Industrial Training, Fairfield, Ohio

PNEUMATIC TECHNICIAN and PNEUMATIC MECHANIC CERTIFICATION REVIEW TRAINING Call for dates. Phone: 513-874-3225 - CFC Industrial Training, Fairfield, Ohio

JOB PERFORMANCE TRAINING Online Job Performance Review - CFC Industrial Training offers online JP Reviews which includes stations 1-6 of the IFPS mechanic and technician job performance tests. Members may e-mail askus@ifps.org for a 20% coupon code off the list price or get the code in our Members Only area for the entire IFPS Job Performance Review; test not included.

LIVE DISTANCE LEARNING JOB PERFORMANCE STATION REVIEW E-mail info@cfcindustrialtraining.com for information.

JUNE 2021

17

I F P S U P D AT E

Certification Testing Locations 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 headquarters if you do not see a location near you. Every effort will be made to accommodate your needs.

If your test was postponed due to the pandemic, please contact headquarters so that we may reschedule.

TENTATIVE TESTING DATES FOR ALL LOCATIONS: July 2021 Tuesday 7/13 • Thursday 7/29 August 2021 Tuesday 8/3 • Thursday 8/26 September 2021 Tuesday 9/14 • Thursday 9/30 October 2021 Tuesday 10/5 • Thursday 10/28

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 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 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

18

JUNE 2021

Tallahassee, FL Tampa, FL West Palm Beach, FL Wildwood, FL Winter Haven, FL 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 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 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 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

CELEBRATING 60 YEARS

NEW JERSEY Branchburg, NJ Cherry Hill, NJ Lincroft, NJ Sewell, NJ Toms River, NJ West Windsor, NJ 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 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 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 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 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 JORDAN Amman, JOR NEW ZEALAND Taradale, NZ

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

P RO D U C T R E V I E W

Enerpac Releases Cylinders, Torque Checker

»

ENERPAC RECENTLY RELEASED a new hydraulic cylinder and a mobile torque wrench testing unit.

RC-Trio hydraulic cylinders Enerpac introduced the next evolution of its RC-Series hydraulic cylinders. The new RC-Trio features a new Trio bearing system for enhanced durability and a hybrid spring-return system for faster retraction and even greater productivity.

The new Trio bearing system includes up to four high-performance wear bands, offering increased resistance to damage, reduced bearing load, and longer cylinder lifespan. The hardened composite material of the bands increases bearing surface area for greater side-load resistance, significantly improving cylinder life. Another durable feature is the new high-performance polyethylene seals that last longer than ever.

Another part of the Trio bearing system is the Trio stop ring, which includes an additional wear band to absorb greater side load. The stop ring is capable of taking full cylinder extension force and, depending on cylinder size, is manufactured in nitrided steel or high-resistance bronze for increased durability. It also features a durable wiper to help prevent contamination from entering the cylinder during retract cycles.

The RC-Trio features a new Trio spring system designed to reduce retraction time. This pre-tensioned return spring system provides retraction up to three times faster (available on 50-, 75-, and 100-ton models). It uses high-strength steel wire to improve spring life. The spring retention design improves serviceability, while allowing higher preload during assembly. Additionally, the spring is easily removed without special tools.

Safe T torque checker Enerpac recently introduced its Safe T torque checker, its first mobile torque wrench-testing unit.

The Safe T torque checker displays a digital readout showing the actual torque output of the wrench within +/- 1% by considering the whole hydraulic system. Features such as a splash-proof display and keypad, and an impact-resistant case provide the essential durability needed in harsh environments.

WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

The rechargeable long-life internal battery provides the freedom for operators to check their whole torque system wherever they are working.

The new unit is compatible with any Enerpac hydraulic torque wrench, including both square drive and low-profile cassette types that fit the envelop and maximum capacity of the STTC. The future-proof design uses the latest technology to ensure convenient use for many years to come.

For more information, visit www.enerpac.com.

LEAD TIMES OF HOURS, NOT WEEKS. HYDRAULIC PUMPS. MOTORS. VALVES. SERVO VALVES. PROPORTIONAL VALVES. When you need to get a machine back up and going yesterday, we’re here for you with our Hydraulex Reman™ line. Remanufactured pumps, motors and valves engineered to deliver OEM level performance and that carry an industry-best 24-month warranty. With our unmatched on-the-shelf inventory of units and parts, and our ability to convert or build units in hours instead of days or weeks, we’re sure to have the unit or part you need right now. Speed and availability redefined.

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JUNE 2021

19

A L L A B O U T VAC U U M

The Science of Vacuum-Cup Forces

By Dane Spivak, Engineering Manager, Davasol Inc.

»

FORCE GENERATED BY vacuum is not an alien concept. It is something we experience throughout our lives, whether it is putting a hand over a vacuum cleaner nozzle or drinking from a straw. We observe it regularly. But how can we break it down to understand, measure, and predict its affects?

This article dives into exactly what vacuum is and how it generates force for vacuum cups to grip a surface.

Vacuum can be defined on earth as a pressure lower than atmospheric pressure in a known volume, atmospheric pressure being the datum point of measurement. The most common vacuum unit of measure used in North America is inches of mercury (inHg), but for the sake of this exercise we’ll use psi because it is more familiar in fluid power. Standard atmospheric pressure at sea level is 14.7 psi. This pressure is created by the weight of the air around us, which can change depending on the altitude and weather. To create a vacuum, a pressure lower than the atmospheric must be generated to establish a differential.

Figure 1 shows a 2-inch diameter, or 1-inch radius, vacuum cup connected to a tube placed on a glass surface. This is our known volume. If you attach a vacuum pump to the tube that generates a 60% vacuum, reducing the pressure inside the cup, the pressure inside the cup decreases to 5.9 psi, and therefore the differential from atmospheric pressure results in 8.8 psi. This 8.8 psi differential pressure – the difference between the pressure inside the cup and the atmospheric pressure outside the cup – is what we use to calculate the holding/gripping force of the vacuum cup. Force is the result of pressure multiplied by area. In the following example, the area is the circular 2-inch diameter vacuum cup, and the vacuum pressure is the differential pressure. The calculations show the holding force in pounds that the vacuum cup exerts coupled to the vacuum source.

Area = πr2 = π×12 = 3.14 in2 Force (F1 ) = Pressure x Area = 8.8lbs/in2 × 3.14in2 = 27lbs From a physical perspective, the atmospheric air pressure under the glass is pushing the glass up against the cup because there is a lower pressure inside. Therefore, vacuum force is limited by the available atmospheric pressure. If the atmospheric pressure is less, such as an area at altitude, then the applied force to the glass would be lower if the pressure inside the Figure 1

20

JUNE 2021

cup remained the same. The take away is that vacuum force from a suction cup is dependant on atmospheric pressure, vacuum-generated pressure inside the cup (vacuum level), and the area of the cup where vacuum is applied to the surface.

Figure 2 shows three 2-inch cups gripping a part, with two of them at a 40° angle. In this example, the cups intend to move directly upward when gripping the part. As we learned from figure 1, we can calculate the lifting force of the middle cup. However, the two outer cups are angled, which affects the amount of vacuum force being applied vertically. Sticking to our differential vacuum pressure of 8.8 psi, we know that the full area of a 2-inch cup applies a force of 27 lbs. But the angled cups apply less vertical lifting force as indicated by the vector arrows in figure 2. The calculations show the affects: F1 = 27lbs F2 = F1×cosθ = 27×cos(40) = 21lbs F3 = F1×cosθ = 27×cos(40) = 21lbs Total Vertical Gripping Force = F1+F2+F3 = 27+21+21 = 69lbs Now consider a full-shear application in which a cup is gripping a part at a 90° angle. From the calculations of figure 2, the angle would go to 90° and therefore zero the force from those cups. But intuition tells us that in a real-life situation, the part could still provide a vertical lifting force because figure 2 ignores the frictional force between the cups and the surface.

In figure 3, the same 8.8 psi and 2-inch cup generates a vacuum gripping force of 27 lbs. The amount of friction force is based on two factors. One is the vacuum gripping force, which applies a force that is 90° to the friction surface. This is typically referred to as the “normal force” when describing friction. Secondly, the coefficient of friction, known as Mu (µ), defines the percentage of the normal force exerted as friction. Coefficients of friction depend on the interaction of the cup with the product surface and how well or poorly they create friction. For example, a rubber cup on a smooth glass surface has a high coefficient of friction, whereas an oily metal sheet has a lower value as it is more likely to slip. The µ value can be found experimentally, though typical shear-gripping applications implement additional safety factors instead of calculating this value. The calculations

Figure 2

Figure 3

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Figure 4

High Performance Filters High Pressure Series based on figure 3 demonstrate the frictional force.

In this example, we chose the µ value arbitrarily and ignored weight and other external forces.

Normal Force (FN ) = 27lbs

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Vertical Vacuum Force = FN×cosθ = 27×cos(90) = 0lbs μ = 0.6

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Vertical Force = Friction Force (FF ) = FN×μ = 27×0.6 = 16lbs

As we see in the calculation from figure 3, the friction force delivers a significant impact to the applied forces of a vacuum cup. So the force created by the vacuum-level pressure and friction each contribute to the output.

Figure 4 uses the same criteria as figure 3 but at an angle of 40°. This allows us to calculate the impact of both forces. Again, we’ve ignored weight and other external forces.

Vacuum Force = FV = 27lbs Vertical Vacuum Force = FV ×cosθ = 27×cos(40) = 21lbs Friction Force (FF ) = FV×µ Vertical Friction Force = FV×µ×cosθ = 27×0.6×cos(50) = 10lbs Total Vertical Force = 21+10 = 31lbs

Vacuum-cup forces are generated by vacuum pressure and friction, which can be calculated for theoretical numbers. However, based on the application and product being gripped, there are other underlying factors to consider, and the appropriate safety factors and designs should be implemented.

This article showcases concepts only. Reach out to a professional for your application needs.  This article is the opinion of the author, Dane Spivak of Davasol Inc., an industrial brand management firm with many clients. One of Davasol’s clients, Vacuforce LLC, based in Indianapolis, partners with the author on this article. Contact Dane Spivak at dspivak@davasol.com.

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Cam lobe radial piston motors are low-speed high-torque motors.

Fed by a pump, the motor rotates either clockwise or counterclockwise by a series of pistons that alternately receive oil under pressure to act on the cam profile.

Given a constant input pressure, the cam profile is calculated to provide constant torque and speed, minimizing torque ripple and cogging. It is not a new technology, but it continues to evolve to fit a variety of needs for mobile equipment as well as tool drives and stationary industrial equipment (figure 1).

Radial piston motors can be used to provide the “direct drive” solution by supplying full torque without the need for high-speed motors connected through gearboxes. Having the radial piston motor connected directly to the work increases efficiency, making more power available at the shaft. Although high-speed motors and gearboxes have the reputation of being a lower-cost solution with simpler integration, there are a number of applications in which cam lobe radial piston technology is a better match to the machine’s requirements.

It is possible to attain the same level of power across a wide range of modular motors at different sizes, putting the technology in reach for different applications just by analyzing the machine’s specifications and determining the right modules to combine to address them. Identifying and specifying 22

JUNE 2021

the max pressure, displacement, torque, speed, and power are the very base elements for motor selection. Beyond this, there are modular options to define depending on the machine specifications and hydraulic system architecture.

Various bearing support types exist, such as wheel flange, splined shafts, shrink disk shafts, or sprocket shafts.

The motors can also adapt to accommodate various types of chassis fixations with corresponding fixation geometries. Options

include integrated brakes: parking, service, combined, caliper, and drum; flanged valves; and integrated pivots. Features that address temperature control, speed, reinforcement, and high-pressure connections open up possibilities for OEMs to integrate highly engineered solutions.

Advantages Cam lobe radial piston motors are compact and fit in a smaller envelope. Their compactness has a

Figure 1

Figure 2

direct benefit for applications that require a lot of torque but have limited space in which to fit it – cutting heads for forestry equipment, harvesters, or sprayers, for example.

Imagine needing to pave a complex job, but when running the machine at the low speeds necessary to accomplish the work, the motor starts to cog and the quality of paving is less than desired. Highly precise movement and constant low speeds without that cogging effect are some of the main benefits of cam lobe radial piston technology. This is a need seen in the off-road and on-road arena – especially with road marking, high rail, or rail telehandler trucks. A creep function can be accomplished by integrating a hybrid mechanical-hydraulic transmission, allowing vehicles to work at low speeds without additional stress on braking and clutching, regardless of engine speed. This makes it possible for auxiliary systems to tap into the power they need to perform work effectively. An additional challenge with on-road vehicles is the need to drive at normal on-road speeds without mechanical losses.

The motor's high starting torque—available for the full speed range— and homokinetic design make precise and consistent rotation possible (figure 2). This, paired with an innate low inertia for smooth and easy direction changes, translates to better consistency in

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Figure 3

work quality for machines such as pavers and road-marking trucks on the construction side and reduced soil and ground damage on the agriculture side. The end benefit is a comfortable and productive end-user experience.

Safety is a real concern for everyone – agriculture, construction, rail and road, newer autonomous machines, and others. Beyond user comfort, the low inertia of this technology delivers an added safety benefit with instant stops and quick direction changes. This makes it easier for drivers to respond quickly to safety concerns (figure 3).

Figure 4

HITACHI FLANGELOCK AND CAP KITS AVAILABLE TM

Cam lobe radial piston motors components into one. This reduces In applications that seek to can be equipped with an internal failure points and simplifies instal- increase uptime and reduce valve that changes the displace- lation on complex architectures. total cost of ownership, reduced ment by deactivating some of the Reducing maintenance also affects unscheduled maintenance can Part number Part description Applicable machines Number of parts Weight (kg) pistons. This reduces torque and total cost of ownership. make a big difference. Innovative Swing hose FlangeLock kit EX3600, EX5600, EX8000 motor 16 x 2062U - red FlangeLock 6.7 increases speed for a givenSWINGFLGLCK2062 flow designs such as Poclain’s and pressure. The valve responds that benefit motors4.5with SWINGCAP2062Applications Swing circuit cap kit EX3600, EX5600, EX8000 MG steerable 16 x 2062 -wheel cap to a pressure signal and makes a When considering just the integrated pivot combine multiple EX3600, EX5600, EX8000 16 x 2462U - purple FlangeLock 7.7 TRAVELFLGLCK2462 Travel hose FlangeLock kit smooth transition from one dis- core technology, anything that components to reduce possible placement to another (figureTRAVELCAP2462 4). needs high torque compact Travel circuit cap kit in aEX3600, EX5600, EX8000 points of16failure x 2462 - capand eliminate 6.4 the Cam lobe radial piston motors package Front could benefit from cam need service gearboxes. These 14 xto 3262U - black FlangeLock attachment EX3600, EX5600, EX8000 8.9 FRONTATTFLGLCK326162 4 x 3261U - black & silver FlangeLock FlangeLock kit are built to go a lifetime with min- lobe radial piston technology. newer designs reduce fabrication 14 x 3262 - cap Front attachment kit EX3600, EX5600, imal regular maintenance.FRONTATTCAP326162 When Sprayers, grapecap harvesters, skidEX8000 time and4 installation cost by9.5elimx 3261 - cap Boom arch hose choosing a modular cam lobe steers, mini loaders, head cutters, inating the need to fabricate an EX3600, EX5600, EX8000 20 x 3262U - black FlangeLock 9.9 BOOMARCHFLGLCK3262 FlangeLock kit radial piston motor, it is possi- crushers, and shredders – the axle, reducing the number of pieces BOOMARCHCAP3262 Boom arch hose cap kit EX3600, EX5600, EX8000 20 x 3262 - cap 11.3 ble to reduce maintenance even applications span a wide number that need to be installed. It also further by incorporating many of industries.

(Continued on page 24) TM

TM

TM

TM

TM

TM

TM

TM

TM

CONTAMINATION CONTROL

Routine and scheduled maintenance of hydraulic systems are vital to getting the most out of your Hitachi Mining Excavator. While maintenance plays the largest role in the prevention of unnecessary machine downtime, it can also expose the hydraulic system to high levels of contamination rapidly decreasing component longevity. The importance of contamination control is sometimes overlooked when performing maintenance due to incorrect practices being used.

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(Continued from page 23) frees up space to streamline design and engine placement. Closer wheel centers and slimmer machines translate to a smaller turn radius and increased productivity for the customer. Reducing the steering radius increases productivity for agriculture machines, helping them to increase precision of work and the acres they are able to cover per hour. In the construction industry, the technology allows for better maneuverability in articulated machines such as miniloaders.

Tracked equipment presents a different set of challenges. It requires a perfectly balanced motor that withstands high axial and radial loads, delivers equal power in forward and reverse, has superior resistance to pollution, and can manage high ground speed without losing torque. Newer technology with high bearing capacity, reinforced seals, and symmetrical design meets these challenges.

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Compatible technology Mobile equipment markets continue to explore zero-emission technology. Hydraulic radial piston cam lobe motor transmissions combined with electropumps can help facilitate the switch from hydrostatic ICE-driven machines to zero-emission solutions. Part and chassis commonality between diesel and electrohydraulic machines can ease the transition and learning curve for the end user and maintenance crews while enabling OEMs to meet environmental and regulation pressure to produce lower or zero-emission machines.

Another persistent trend is integrating more functionality into the motors, enabling OEMs to do more with one component. High-resolution sensors and integrated braking solutions such as parking, dynamic, or combined options augment the precision of the motor, making it possible for the technology to meet the stringent safety and precision requirements of autonomous vehicles. Oil-immersed integrated brakes make it possible for grape harvesters to meet even more challenging inclines. They allow sprayers to meet new roading regulations when using higher speeds to get from field to field, and they give mining vehicles the stopping power needed for steep inclines (figure 5).  WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

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Thompson Dayton Steel Service 120 Royall Street Canton, MA 02021 Phone: 781-828-8800 Fax: 781-828-5082 Email: eryan@thompsonsteelco.com Web: www.thompsondayton.com

Tribute, Inc. 1696 Georgetown Rd. F Hudson, OH 44236 Phone: 330-656-3006 Fax: 330-656-3464 Email: tribute@tribute.com Web: www.tribute.com

Thompson Pump 4620 City Center Dr. Port Orange, FL 32129 Phone: 386-767-7310 Fax: 386-761-0362 Email: sales@thompsonpump.com Web: www.thompsonpump.com

Trico Corporation 1235 Hickory St. Pewaukee, WI 53072 Phone: 262-691-9336 Fax: 262-691-2576 Email: cservice@tricocorp.com Web: www.tricocorp.com

Thornton Inc./Mettler-Toledo 1432 Main St. Waltham, MA 02451 Phone: 781-839-6400 Fax: 781-890-5507 Email: info@thorntoninc.com Web: www.thorntoninc.com

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Tobeyco Mfg. Co., Inc. Federal Brass Div. 165 Cedar St. Corning, NY 14830 Phone: 607-962-6054 Fax: 607-962-8871 Email: suztobeyco@stny.rr.com Tobul Accumulator, Inc. 61 Innovation Drive Bamberg, SC 29003 Phone: 803-245-2400 Fax: 803-245-2636 Email: sales@tobul.com Web: www.tobul.com Tolomatic, Inc. 3800 County Rd. 116 Hamel, MN 55340 Phone: 763-478-8000 Toll Free Phone: 800-328-2174 Fax: 763-478-8080 Email: sales@tolomatic.com Web: www.tolomatic.com TopWorx 3300 Fern Valley Rd. Louisville, KY 40213 Phone: 502-969-8000 Fax: 502-969-5911 Email: info@topworx.com Web: www.topworx.com TPC Pneumatics 12411 McCann Dr. Santa Fe Springs, CA 90670 Phone: 800-347-3954 Fax: 562-944-3785 Web: www.tpcpage.com TR Engineering Inc. 1350 Green Hills Road #10 Scotts Valley, CA 95066 Phone: 831-430-9920 Fax: 831-430-9989 Email: rromero@TREngineering.com Web: www.TREngineering.com Trans Metrics, Div. Of United Electric Controls 5325 Naiman Pkwy.E Solon, OH 44139 Phone: 440-248-2229 Fax: 440-248-7780 Email: sales@trans-metrics.com Web: www.trans-metrics.com Trelleborg Sealing Solutions 2531 Bremer Road Fort Wayne, IN 46803 Phone: 260-749-9631 Fax: 260-749-4844 Email: tssusa@trelleborg.com Web: www.trelleborg.com/seals

TSD Integrated Controls 3500 Anapolis Ln. Plymouth, MN 55447 Phone: 763-509-2107 Fax: 763-694-2197 Web: www.tsdcontrols.com TTI, Inc. P.O. Box 1073 Williston, VT 05495 Phone: 802-863-0085 Fax: 802-863-1193 Email: sales@ttiglobal.com Web: www.ttiglobal.com Tubes n Hoses 820 N. Dallas Ave Lancaster, TX 75146 Phone: 972-923-0766 Fax: 972-332-4119 Email: sales@tubesnhoses.com Web: www.tubesnhoses.com Turn-Act 105 Commerce Way Westminster, SC 29693 Phone: 864-647-9521 Fax: 864-647-9574 Email: CAP_CustomerService@itt.com Web: www.turn-act.com Turner hydraulics 1605 Industrial Dr. Carlisle, PA 17013 Phone: 800-222-2543 Email: cjohnson@turnerhydraulics.com Web: www.turnerhydraulics.com Tuthill Coupling Group 1000 West Bagley Rd. Berea, OH 44017 Phone: 440-826-1115 Fax: 440-826-1105 Email: Hansencouplings@tuthill.com Web: www.tuthill.com

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Ultra Electronics, Measurement Systems Inc. 50 Barnes Park North Wallingford, CT 06492 Phone: 203-949-3500 Fax: 203-949-3598 Email: sales@ultra-MSI.com Web: www.ultra-msi.com Ultraflo Corporation A Subsidiary of Bray Int’l. Inc. #8 Trautman Industrial Drive Ste. Genevieve, MO 63670 Phone: 800-950-1762 Fax: 573-883-8882 Email: ultraflo@ultraflovalve.com Web: www.ultraflovalve.com ULVAC Technologies, Inc. 401 Griffin Brook Dr. Methuen, MA 01844 Phone: 978-686-7500 Fax: 978-689-6300 Web: www.ulvac.com Uniflex of America, LLC 1088 National Parkway Schaumburg, IL 60173 Phone: 1-847-519-1100 Fax: 1-847-519-1104 Email: sales@uniflex.de Web: www.uniflexusa.com Unique Automation LLC 612 East Main Street Palmyra, NY 14522 Phone: 315-597-4900 Fax: 315-597-4953 Email: C.Schaufelberger@ uniqueautomation.com Web: www.uniqueautomation.com

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Universal Components, Inc. (UCI) 1313 Hall Spencer Rd. Rock Hill, SC 29730 Phone: 803-324-5176 Fax: 803-324-2640 Web: www.ucimfg.com

V

V&P Hydraulic Products 1162 Peachblow Rd. Lewis Center, OH 43035 Phone: 740-548-5181 Fax: 740-548-6206 Email: mikeueber@vphyd.com Web: www.vphyd.com

Universal Flow Monitors, Inc. 1755 E. 9 Mile Rd P.O. Box 249 Hazel Park, MI 48030 Phone: 248-542-9635 Fax: 248-398-4274 Email: ufm@flowmeters.com Web: www.flowmeters.com Universal Grinding Corporation 1234 West 78th St. Cleveland, OH 44102 Phone: 216-631-9410 Fax: 216-631-5589 Email: monica@universalgrinding.com Web: www.universalgrinding.com

Vac-Cubes 536 E. Tarpon Ave., Suite 5 Tarpon Springs, FL 34689 Phone: 727-944-3337 Fax: 727-945-0079 Email: info@vac-cube.com Web: www.vac-cube.com Vaccon Company., Inc. 9 Industrial Park Road Medway, MA 02053 Phone: 508-359-7200 Fax: 508-359-0177 Email: eferri@vaccon.com Web: www.vaccon.com

TECHNOLOGIES CORP.

TWG-Dover 11135 S. James Ave. Jenks, OK 74037-1731 Phone: 918-298-8300 Email: esallee@team-twg.com Web: www.team-twg.com U UE Systems Inc. 14 Hayes St. Elmsford, NY 10523 Phone: 914-592-1220 Fax: 914-347-2181 Email: info@uesystems.com Web: www.uesystems.com Ultra Clean Technologies Corp.

1274 Highway 77 Bridgeton, NJ 08302 Phone: 800-791-9111 Fax: 856-453-4975 Email: briley@ultracleantech.com Web: www.ultracleantechnologies.com

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41

MANUFACTURERS 2021 DIRECTORY

T-Lon Products Inc 1110 Richards Road Hartland, WI 53029 Phone: 262-367-2333 Fax: 262-367-8159 Email: bolson@t-lon.com Web: www.t-lon.com

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Warren Electric Corp.

36 Franklin St. Warren, RI 02885 Phone: 401-245-3700 Fax: 401-245-9331 Email: wec@warrene.com Web: www.warrene.com

Waterclock Engineering 342 N Water St, #600 Milwaukee, WI 53202 Phone: 888-902-2297 Email: info@waterclockeng.com Web: www.waterclockeng.com WC Branham, Inc. 398 Troy Street River Falls, WI 54022 Phone: 715-426-2000 Fax: 715-426-1400 Email: askwcb@wcbranham.com Web: www.wcbranham.com Web Seal Inc. 15 Oregon Street Rochester, NY 14605-3094 Phone: 585-546-1320 Alt Phone: 800-366-1320 Fax: 585-546-5746 Email: sales@websealinc.com Web: www.websealinc.com

WEH Technologies Inc. 24903 Laguna Edge Drive Katy, TX 77494 Phone: 832-331-0021 Fax: 281-712-2664 Email: sales@weh.us Web: www.weh.us Weiss Instruments, Inc. 905 Waverly Ave. Holtsville, NY 11742 Phone: 631-207-1200 Fax: 631-207-0900 Email: sales@weissinstruments.com Web: www.weissinstruments.com Wen Technology, Inc. 8411 Garvey Drive, Suite 117 Raleigh, NC 27616 Phone: 919-954-1004 Fax: 919-954-1009 Email: pgubbins@wentec.com Web: www.wentec.com West Coast Calibration, Inc. 224-122 Reindollar Ave. Marina, CA 93933 Phone: 831-883-3985 Fax: 831-883-3986 Email: service@wccal.com Web: www.wccal.com

Western Filter Corp.

26235 Technology Dr. Valencia, CA 91355 Phone: 661-295-0800 Fax: 661-295-8443 Email: sales@westernfilter.com Web: www.westernfilter.com Western Fluid Power, LLC 4309 N.W St. Helens Rd. Portland, OR 97210 Phone: 503-228-6666 Fax: 503-228-7318 Web: www.hydrauliccomponents.com Western Hydrostatics, Inc. 1956 Keats Dr. Riverside, CA 92501-1747 Phone: 909-784-2133 Fax: 909-784-8423 Email: sales@weshyd.com Web: www.weshyd.com Western Integrated Technologies 7651 S. 190th Street Kent, WA 98032 Phone: 800-456-6248 Fax: 206-988-6773 Email: sales@westernintech.com Web: www.westernintech.com White Drive Products, Inc. P.O. Box 2700 110 Bill Bryan Blvd.

Hopkinsville, KY 42240 Phone: 270-885-1110 Fax: 270-886-8462 Email: infousa@whitedriveproducts. com Web: www.whitedriveproducts.com Whitman Controls Corp.

201 Dolphin Road Bristol, CT 06010 Phone: 860-233-4401 Fax: 860-583-5293 Email: info@whitmancontrols.com Web: www.whitmancontrols.com Whitmore 930 Whitmore Drive Rockwall, TX 75087 Phone: 972-771-1000 Fax: 972-722-2108 Email: sales@whitmores.com Web: www.whitmores.com WIKA Instrument Corp.

1000 Wiegand Blvd.

Lawrenceville, GA 30043 Phone: 770-513-8200 Fax: 770-338-5118 Email: info@wika.com Web: www.wika.com Wilkes & McLean Ltd. 600 Estes Ave. Schaumburg, IL 60193 Phone: 847-534-2000 Fax: 847-534-2016 Email: info@wilkesandmclean.com Web: www.wilkesandmclean.com

Williams Machine and Tool 204 Plastic Lane Monticello, IA 52310-9472 Phone: 319-465-3537 Fax: 319-465-5279 Email: sales@energymfg.com Web: www.williamsmachineandtool. com

WP Associates 211 Hickory Point Buckhead, GA 30625 Phone: 706-991-9946 Email: wpassociates@plantationcable.net Y

Zatkoff Seals & Packings P.O. Box 486 Farmington, MI 48332 Phone: 248-478-2400 Fax: 248-478-3392 Email: info@zatkoff.com Web: www.zatkoff.com

Wilson Fluid Power Solutions 16301 Addison Road Addison, TX 75001 Phone: 972-931-8666 Fax: 972-248-1177 Web: wilson-company.com

ZEKS Compressed Air Solutions 302 Goshen Pkwy.

West Chester, PA 19380 Phone: 610-692-9100 Fax: 610-692-9192 Email: zeks@zeks.com Web: www.zeks.com

Winters Instruments 600 Ensminger Rd. Buffalo, NY 14150 Phone: 716-874-8700 Fax: 716-874-8800 Email: usasales@winters.com Web: www.winters.com

Zemarc Corporation 6431 Flotilla Street Los Angeles, CA 90040 Phone: 323-721-5598 Fax: 323-722-2220 Web: www.zemarc.com Email: sales@zemarc.com

Winters Instruments 121 Railside Road Toronto, Ont CANADA M3A 1B2 Phone: 1-800-Winters Fax: 416-444-8979 Email: sales@winters.com Web: www.winters.com Wojanis Supply Company 1001 Montour West Industrial Park Coraopolis, PA 15108 Phone: 724-695-1415 Fax: 724-695-1203 Email: dougg@wojanis.com Web: www.wojanis.com Womack Machine Supply Company 13835 Senlac Drive Farmers Branch, TX 75234 Phone: 800-569-9800 Email: sales@womack-machine.com Web: www.womackmachine.com Woodward HRT 25200 West Rye Canyon Rd. Santa Clarita, CA 91355 Phone: 661-702-5224 Fax: 661-702-5100 Email: Mark.Tandy@woodward.com Web: www.r-ddv.com World Wide Fittings 600 Corporate Woods Parkway Vernon Hills, IL 60061 Phone: 847-588-2200 Fax: 847-588-2212 Email: sales@worldwidefittings.com Web: www.worldwidefittings.com World Wide Metric 37 Readington Road Branchburg, NJ 08876 Phone: 732-247-2300 Fax: 732-247-7258 Email: sales@worldwidemetric.com Web: www.worldwidemetric.com Worthington AG Parts 122 St. George Lane Sikeston, MO 63801-8705 Phone: 800-637-5165 Fax: 573-471-2693 Email: dbell@worthingtonagparts.com Web: www.worthingtonagparts.com

Yates Cylinders 23050 East Industrial Drive St. Clair Shores, MI 48080 Phone: 586-778-7680 Email: sales@yatesind.com Web: www.yatescylinders.com York Precision Machining & Hydraulics 706 Willow Springs Lane York, PA 17406 Phone: 717-764-8855 Fax: 717-767-2798 Email: kreichard@yorkpmh.com Web: www.yorkpmh.com Youli-America 222 S. Navigation Blvd.

Corpus Christi, TX 78405 Phone: 713-861-8041 Fax: 361-883-3893 Email: service@youli-america.com Web: www.youli-america.com Young Powertech Inc. 3060 Plaza Drive #107 Garnet Valley, PA 19061 Phone: 610-558-0760 Fax: 610-558-0762 Email: info@youngpowertech.com Web: www.youngpowertech.com Young Touchstone 2825 Four Mile Rd. Racine, WI 53404 Phone: 262-639-1013 Fax: 262-639-1013 Email: chorton@wabtec.com Web: www.youngtouchstone.com Yuken/ALA Industries Limited (North America Master Distributor) 3410 Delta Drive Portage, IN 46385 Phone: 877-419-8536 Fax: 219-477-4194 Email: alaindustries@yuken-usa.com Web: www.yuken-usa.com

Zenith® Pumps 5910 Elwin Buchanan Drive Sanford, NC 27330 Phone: 919-775-4600 Fax: 919-774-5952 Email: zenithpumps@parker.com Web: www.zenithpumps.com Zero-Max 13200 6th Ave. N. Minneapolis, MN 55441 Phone: 763-546-4300 Fax: 763-546-8260 Email: sales@zero-max.com Web: www.zero-max.com Zinga Industries, Inc. 2400 Zinga Dr. Reedsburg, WI 53959 Phone: 608-524-4200 Fax: 608-524-4220 Email: zinga@zinga.com Web: www.zinga.com

MANUFACTURERS 2021 DIRECTORY

Webtec LLC 1290 E. Waterford Ave. St. Francis, WI 53235 Phone: 1-800-932-8378 Email: sales-us@webtec.com Web: www.webtec.com

West Coast Fluid Power 5370 S. Watt Ave. Suite 300 Sacramento, CA 95826 Phone: 800-532-8837 Fax: 800-370-0447 Email: sales@comoso.com Web: www.comoso.com

ZMC Corporation 1255 Stone Dr. San Marcos, CA 92069 Phone: 760-471-0440 Fax: 760-471-0902 Email: btaylor@zemarc.com Web: www.zmccorporation.com ZSI 42550 Executive Drive Canton, MI 48188 Phone: 800-323-7053 Fax: 734-844-0066 Email: twright@zsi-inc.com Web: www.zsi-inc.com

Z Zander A Division of Parker-Hannifin Corp.

5900-B Northwoods Pkwy.

Charlotte, NC 28269 Phone: 800-543-0851 Fax: 678-924-1111 Email: zanderusa@zanderusa.com Web: www.zanderusa.com

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JUNE 2021

43

COVER STORY

Riding

THE

RAILS

Pneumatics Is Essential to Train Travel

By Frank Gevers, Director, Railway, Fluid Control and Pneumatics at Emerson

From air preparation to operation and passenger experience, pneumatic products are found throughout passenger and freight trains.

Pneumatics is used for everything from brake control, suspension, and leveling, to air conditioning and toilet control.

Rail car manufacturers use pneumatic products for these applications because they’re reliable, durable, cost-effective, and provide benefits that go beyond their high performance.

In addition to improving the operation and passenger experience, selecting the right pneumatic products can significantly extend maintenance intervals and minimize downtime while reducing maintenance costs and energy consumption.

Whether freight or passenger, railway pneumatics begins with Reliable a reliable, dry air supply. Moisture air can wash out grease and cause preparation corrosion or lead to ice buildup at low temperatures. This can disable door systems or, even worse, freeze valves in the brake control circuit, all of which results in trains being taken out of service.

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Most air dryers use a granular adsorption medium. Unfortunately, the shock and vibration from rail operations can cause channeling, air bypass, and dust generation or even lead to a breakdown of the granulate bed and a significant reduction in drying performance. This results in a shorter service life, requiring more frequent replacement of the adsorption medium.

The typical service interval for air dryers is less than two years. However, new developments in drying technology can extend that service life and reduce maintenance costs while increasing performance. For example, Emerson’s AVENTICS RDD air dryer series uses rolled-up desiccant drying technology that provides a consistent, highly open porous structure throughout the media, resulting in superior moisture uptake performance. Resistant to vibration and excessive water loading, the air dryer works in both horizontal and vertical orientations for more installation flexibility. Furthermore, it provides a service interval of at least eight years (or greater than 25,000 operating hours) instead of two years.

The design is based on two columns containing the drying medium inside easy-to-replace

cartridges, where one column is always drying the air and the second one is being regenerated by purge air. Once one column is saturated and must be regenerated, control valves switch the air supply between the two columns automatically. The high moisture uptake and improved kinematics reduce the purge loss compared to conventional air dryer technology (less than 15%), leading to less air consumption and more energy savings.

In both passenger and freight train operation, safety Train operation comes first. The technology used to control leveling and brake control, chassis suspension, and pantograph control needs to be extremely reliable and durable enough to withstand rugged environmental conditions and extreme temperature ranges. Components must be easy to maintain and need to have a long life cycle. Intelligent, durable, and low-maintenance pneumatic components are ideal here for fulfilling a wide range of applications on trains.

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air for braking on trains originated in the mid1800s. More than 150 years later, pneumatics is still the best technology to use for brake control; it’s easy to maintain, exceptionally reliable, and intrinsically safe.

One of the latest key components in a railway brake system is the electropneumatic (EP) pressure regulator, which provides precise control of pressure and flow with dynamic regulation – especially important for brake control.

In Emerson’s ED05 Rail Series EP pressure regulator, the direct electromagnetic actuation of the integrated poppet valve allows for precise true proportional control with a high flow rate and combines dynamics, precision, and excellent repeatability with extreme durability.

It provides robust poppet valve technology that does not require any special air quality.

A large cross section and a soft-sealing proportional valve seat make the valve durable and resistant to contamination.

Some suppliers like Emerson also make it easy to order the complete pneumatic brake control unit. All the required components, including safety valves, pressure switches, ball valves, and pressure sensors, are preassembled and tested on a ready-to-install control manifold for the service, emergency, and spring-loaded brake functions on a train.

Chassis suspension and leveling.

Besides braking systems, pneumatics plays a key role in chassis suspension systems, such as the pneumatic control of air springs. An electronic leveling valve provides significant benefits over conventional manual leveling valves. It primarily consists of one proportional valve, two switching valves, and control electronics with sensors. The bus interface makes controlling easy and allows for life-condition monitoring. Control electronics optimize the control and switching behavior of the integrated valves while minimizing air consumption.

The Emerson ED05 Rail Series electropneumatic pressure regulator is a crucial component for pantographs, brake control, and suspension leveling.

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When selecting an air dryer, consider whether the drying medium is integrated into an easyto-replace cartridge, which also saves maintenance time.

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It can be advantageous to partner with a supplier that can customize hardware and software to exact application requirements. These customized, ready-to-install assemblies deliver benefits over discrete components that must be assembled and adjusted separately. In one example, a manufacturer designing train cars for the bustling London passenger rail system needed a faster alternative to complex and often time-consuming mechanical air suspension.

Emerson customized an electronic leveling valve that not only adjusts the train height to the platform level more quickly, it significantly decreases train air consumption and lowers operating costs.

Pantograph control and actuation.

On electrically powered trains, when it comes to pantograph control and actuation, there’s absolutely no room for compromise. Pantographs must work in all conditions at any speed. The primary challenge is to constantly maintain the contact between the catenary cable and the pantograph’s carbon strip without pressing against overhead lines too forcefully, otherwise they will rapidly wear or even rip. Pneumatic control solutions provide the dynamic performance this precise application requires. Compared with electromechanical solutions, quality pneumatic solutions are virtually wear-free.

Emerson, for instance, supplies a preassembled pneumatic assembly for pantographs to a Swiss company that has made pantographs for over 100 years. The pneumatic control solution, which consists of a valve, precision pressure regulator, pneumatic bellow actuator, and air preparation, presses the pantograph’s carbon strip against the overhead line with just enough pneumatic force to maintain contact, even when tracks are uneven. These particular pantographs (Continued on page 46)

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(Continued from page 45) are approved for speeds up to approximately 143 mph (230 kph), proving just how effective the assemblies and pneumatic solutions truly are. In addition, further developments involving EP pressure regulators have proven their performance up to speeds of approximately 217 mph (350 kph).

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JUNE 2021

TO PERFORM

From the moment passengers enter the train to the moment Passenger experience they exit, a range of pneumatic components ensure their experience is as safe and comfortable as possible.

Starting at the train door, rodless pneumatic cylinders provide reliable actuation. And for those trains that need a step to board quickly and safely, sensor-controlled cylinders in the sliding step provide exact extension and retraction to ensure the step precisely lines up with the platform.

Once passengers are in their seats, pneumatic components actuate and control HVAC systems, keeping the ride comfortable. Pneumatic components that instantly close the fresh-air intake help protect passengers from pressure changes when high-speed trains encounter oncoming trains or enter and exit tunnels. If the fresh-air intake is not properly and quickly closed, pressure waves can enter passenger cabins.

If passengers must leave their seat during the journey for a restroom break, Emerson’s electromagnetic valves ensure a proper functioning toilet. The valves are used to control several different functions that help provide a comfortable experience every time.

No matter how well pneumatic components function, it Railway standards is equally important that they meet current railway-specific standards and requirements. These include ratings for electromagnetic compatibility (EN 50121-3-2), corrosion resistance, fire protection (EN 45545), shock and vibration (EN 61373), temperature, and more. It’s crucial to work with an expert supplier who knows the industry and offers support and products that comply with the latest global standards – for individual components or complete plug-and-play subsystems.

From braking to actuators, airflow, and control, pneumatics can do it all. Whether a solution is needed for new trains or a refurbishment project, pneumatics designed specifically for the rail industry helps ensure all specifications can be met successfully.  WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

AIR TEASER

New problem

Find the Cylinder Rod

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

»

DURING THE SCHOOL year of 1975-1976 and with the help of my students, we built the first fully functional hybrid car using two ten-gallon accumulators with a Brady GT body on a VW chassis.

One of our challenges was to find how much actual hp we needed to overcome the various resistances while moving the vehicle at 60 mph. One of our options was to use an oscilloscope with a load cell, but that would require a generator in the back of our tow vehicle.

Remember this was 1975. A second option was to use a cylinder by placing a little oil in the rod end and putting it in series with a tow rope. Then we could use a pressure gauge with a long hose and read the pressure as we were driving. The oil would prevent the cylinder from bottoming out and not giving a true pressure reading.

The challenge in this Air Teaser is to solve for the rod diameter using a 3-inch bore cylinder, where the resistance would produce a pressure on the gauge that would be equal to the hp at 60 mph.

Helpful formula: hp = (pounds of pull x feet/sec.) / 550

Solution to the April 2021 problem: Calculating with Car Specs Find compression ratio: 10 psi + 14.7 = 1.68 : 1 C.R. 14.7 Area of piston: A = D²x 0.7854 4² x 0.7854 = 12.57 in.² Volume per stroke = area x stroke 12.57 in.² x 3.46 in. = 43.49 in.³ / piston Volume = 43.49 in.³ x 8 pistons / 2 (since the engine only pulls in air every other rev.) = 173.96 in³ / firing cycle Volume / minute: 173.96 in.³ x 6,000 rpm = 1,043,760 in³/ minute 1,043,760 in.³ / 1728 (in³ / ft³) = 604.03 scfm without boast 604.03 scfm x 1.68 (C.R.) 1014.77 scfm (28,735.09 nlpm) This displacement would be your 350 V8 engine (347.94) or today’s 5.7-liter engine. The diameter of the pistons and stroke may vary.

Visit fluidpowerjournal.com/air-teaser to view previous problems.

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JUNE 2021

47

TEST YOUR SKILLS

The Function of a

PRIME MOVER A complete hydraulic system must include an initial energy source. This energy source is referred to as the prime mover, and it must be considered when maintaining or repairing any hydraulic system. The prime mover could be as simple as a manually operated lever on a jack where the input energy is human effort, or it could be a massive diesel engine on earth-moving equipment or on a merchant marine vessel. In either case, there must be energy entering the system to push the fluid doing work. In mobile equipment, the prime mover is often an internal combustion engine.

Hydraulic pumps are connected to the engines and convert the mechanical energy at the crank shaft to hydraulic energy.

Hand pump

Electric motor

Methods for connecting a pump to an internal combustion engine vary with each application, but there are some common considerations. The pump shaft and the shaft to which it is connected must be properly aligned to prevent damage. With smaller engines, there are mounting adapters where one side is bolted directly onto the engine face and the other side is machined to accept the pump with an appropriate flexible coupling. These are designed to keep the shafts properly aligned.

If a pump mount is not available, a foot mount can be used with a flexible coupling or a drive shaft. If a drive shaft is used, it is critical that the shaft on the prime mover and the shaft on the pump be properly aligned. A drive shaft uses a set of Cardan universal joints (figure 1) to couple and align the shaft of the prime mover with the shaft of the pump. The yokes of the Cardan joints must be in phase and the drive and driven shafts must be parallel to prevent vibration.

Sometimes the drive shaft is connected directly to the harmonic balancer on the vehicle engine through a modified radiator. The angle of the drive shaft from the pump to the harmonic balancer needs to be considered. The maximum angle varies with the engine rpm.

Electric motors are the prime movers in many mobile hydraulic applications. Smaller systems use direct current (DC) motor-driven power packs (figure 2) that are powered off the vehicle electric system.

This provides the advantage of on-demand power, using the energy stored in the vehicle’s battery. The engine may be turned off while the hydraulics are

48

JUNE 2021

Combustion engine

Engine motor mount

Foot mount

Figure 1: Cardan universal joint

Figure 2: DC power pack

Tractor PTO

being used, saving energy and making for a quieter environment. In this case the small hydraulic pump is directly coupled to the electric motor. A manifold holds some directional and relief functions along with porting and connection to the attached reservoir.

Larger electric motors are used, especially in marine applications, where alternating current is available from generators. Mounting pumps to electric motors requires the same concerns about alignment as with internal combustion engines. Electric motors that have the correct bolt pattern can be equipped with a C-face adapter (figure 3), which is made to properly couple and align a hydraulic pump. The C-face adapter bolts directly to the motor and the pump is then mounted on the adapter. The adapter is machined to accept and properly align a pump with a matching flange face.

If a C-face motor and adapter are not available or there are other physical constraints, a foot mount adapter can be used. It is critical that the shafts of the pump and motor are properly aligned.

Gearboxes When the prime mover is an internal combustion engine that is the power source for the entire vehicle, the hydraulic system may be an auxiliary function and will be connected to the prime mover through a power take-off (PTO) attached to the vehicle transmission.

The PTO is a gearbox (figure 4) in which the shaft speed (rpm) may be different than the engine rpm.

The power potential of the PTO is dependent on its gear ratio and the torque rating of the shaft.

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

TEST YOUR SKILLS

Figure 3: C-face adapter

Figure 4: Chelsea PTO

1. When using a foot mount to connect a prime mover to a pump: a. Alignment is necessary. b. Alignment becomes unnecessary. c. Any extra torque is absorbed by the hold down bolts. d. A four-bolt mounting pattern is required. e. Axial parallelism is diminished.

2. The prime mover: a. Should be much larger than the pump. b. Is always a diesel engine. c. Operates only in a counterclockwise rotation. d. Is driven by the hydraulic motor. e. Is the energy source that drives the pump.

See page 55 for the solutions.

Figure 5: Twin Disc 4-station gearbox

An internal combustion engine may be the prime mover for a number of hydraulic systems and so may use a multistation gearbox (figure 5).

Both internal combustion engines and electric motors may require some type of gearbox.

The power transmitted by a hydraulic pump is a product of both the flow rate and the pressure. The power delivered by the prime mover is determined by the rotational force (torque) available and the rpm. If the output of the prime mover does not match the requirements of the hydraulic system, a gearbox can reduce the speed and increase the torque, or it could increase the speed and decrease the torque.

All gearboxes, whether used to increase or decrease speed, have some degree of mechanical inefficiency. This inefficiency will consume some of the power from the prime mover and must be understood when gearing is used.

For example, a hydraulic system requires 45 lpm at 10 MPa (12 gpm at 1,450 psi). The hydraulic system operates at 85% overall efficiency requiring about 9 kW (12 hp). The truck engine can easily supply this much power at 900 rpm. However, the pump requires 1,800 rpm to supply the flow. Raising the engine rpm to 1,800 would provide the necessary flow but would waste a lot of energy. By using a PTO with a step up gear ratio of 2:1, the engine can run at 900 rpm while the PTO shaft would drive the pump at 1,800 rpm. If the PTO has a mechanical efficiency of 90%, the power draw from the engine would have to increase to 10 kW (13 hp). 

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JUNE 2021

49

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Air Driven Compact Gas Boosters

Air Pressure Amplifiers

PRODUCT LINE OVERVIEW

Flow Meters

50

Air Driven Gas Boosters

High Pressure Valves

JUNE 2021

Electric Driven Gas Boosters

Package Systems

Hydraulex Repair Services Our Repair Services Brochure covers the types of components (pumps, motors, final drives, valves, control cards, amplifiers and cylinders) we can repair, why we’re an excellent choice for your repair needs, and also how the repair process works. View or download it by visiting our website at www.hydraulex.com.

Hydraulex Toll Free: 800.422.4279 Tel: 586.949.4240 Email: sales@hydraulex.com www.hydraulex.com

Compressed Air Filtration

Hydraulics International, Inc. is a leading manufacturer of air and electric driven gas boosters, air driven liquid pumps, air pressure air amplifiers, high pressure valves, turbine flow meters and packaged systems. Our products offer the most comprehensive range of models to the fluid power industry whether is measured by ultimate pressure, discharge flow rate or fluid compatibility.

Request a FREE copy today!

DISTRIBUTOR INQUIRIES WELCOME

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.

Hydraulics International, Inc. 818-407-3400 www.hiigroup.com

La-Man Corporation 800.348.2463 www.laman.com

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SPECIAL AD SECTION

Hydraulic Flanges and Components

304 & 316 Stainless Steel Liquid Level Gages

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/fpj

NEW 2021 Product Catalog Pressure Components Inc., providing high quality components since 1985, is excited to announce our 2021 catalog with new offerings to run your business.

PCI prides itself on exceptional customer service. Let us be your “trusted partner.”

440-349-4020 sales@pressurecomponents.com www.pressurecomponents.com

Corrosive resistant properties make stainless steel gages suitable to a variety of applications. Oil-Rite offers 304 and 316 stainless steel liquid level gages in sizes from 3" to 60". A red line on a white background enhances liquid level visibility. Available with adapters and thermometer. Visit Oil-Rite’s online product catalog for new cut sheets and detailed information.

Oil-Rite Corporation PO Box 1207 Manitwoc WI 54221-1207 Phone: 920.682.6173 Email: sales@oilrite.com www.oilrite.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

Make Your Voice Count!

LET US HEAR FROM YOU! The 2021 salary survey from Fluid Power Journal and the International Fluid Power Society is live now until June 30. The survey provides a glimpse of industry pay levels and other meaningful information about fluid power professionals like you.

We encourage everyone in fluid power to complete the anonymous survey and be counted. It takes less than 10 minutes. We’ll publish the findings in September’s Fluid Power Journal.

Take the survey by visiting www.fluidpowerjournal.com/2021-survey.

WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

JUNE 2021

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Clean Air Act Battling Contaminants in Pneumatic Components

By Mike Parzych, Product Marketing Manager, Norgren

A

ctuators, air motors, grippers, and many other pneumatic components in almost all industries use compressed air, but performance requirements and design parameters vary widely. In life sciences, for example, compressed air drives small, lightweight, high-precision respirators.

Patient-care devices require the same reliability and controllability as rail-car braking systems, automotive assembly, metal stamping, food and beverage dispensing, packaging, commercial vehicles, industrial automation, and energy production. Despite the different scale of each of these applications and the unpredictability of the environmental temperatures in which they operate, they all depend on precision and control.

Automotive manufacturing, for example, employs compressed air for the painting, cleaning, press-room, and assembly area production lines, and it’s commonly used to operate robotic end effectors. Compressed air is essential to create auto parts because it lifts, positions, and moves fastening machines. But no matter the application, for the system to perform as required with the longest possible service life, the air supply must be free of contaminants.

Oil, for example, can keep paint from adhering to surfaces, and it can cause cracking, flaking, beading, or future corrosion. Unremoved water can stick to pipe walls and block the path of the compressed air. Solid particles such as rust can clog nozzles and compromise the surface of the finished product.

In machine shops, where compressed air operates grinding machines, air guns, and water recovery units, if the air contains too much moisture it can condense on colder surfaces, causing corrosion in the metal work piece or the tooling.

In short, because of the versatility and variety of pneumatic systems, regardless of the 52

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Regulator.

Precision regulator.

application requirements, compressed air must be clean, dry, and delivered at the appropriate pressure. Unless contaminants are filtered out, they compromise proper operation and shorten the life of the equipment.

Compromising compressed air Compressing atmospheric air converts it into potential energy that can be stored, distributed, and used as a source of power for pneumatic systems, tools, and processes. This compressed air retains nitrogen, oxygen, other gasses, water, hydrocarbon vapor, and solid particulates such as dust or heavy dirt measuring as much as a millimeter. Compressing this mix concentrates solid contaminants and heats the air so that it holds more water vapor. In addition, the oil that lubricates the compressor can enter the air stream as fine mist, aerosol, or vapor. Even air leaving oil-free compressors can pick up oil vapors from atmospheric air and pass them into the air-distribution system.

The now-hot air leaves the compressor, passing through a heat exchanger into an air storage receiver and distribution pipework. As the air cools, water and oil vapor condense and turn to liquid or emulsions. An efficient condensate management drainage system can remove these elements. But entrenched solid particulates and any remaining water and oil vapor travel downstream into the distribution system. The air can then pick up even more contaminants such as rust and debris from old receivers, treatment equipment, and pipework.

There is a clear connection between the presence of moisture, particulate, and oil in compressed air and a whole range of disruptions such as less-efficient processes and damaged tools and equipment.

To remove the water and contaminants present in compressed air requires intervention just before or after the compressor but before the air reaches the tools and equipment. Operators can apply many point-of-use air-preparation components at this point. One is an inlet filter, which prevents dirty ambient air particles from entering the compressor in the first place. Another component is a water-removal filter installed between the outlet and the air receiver; it reduces the moisture in the stored air. As air in the receiver cools and vapor condenses, the liquid water and emulsions fall to the bottom to be drained. After the receiver, a coalescing filter can remove oil aerosols and water carried from the compressor. Another installation to consider is a general-purpose filter. When placed at the main header, it removes water and particles 40 microns and larger.

The air is compressed, moisture and oil vapors are condensed and drained, water is removed, and large particles are filtered out. This general level of air preparation may be enough for many industrial uses, but tools can extend their life and effectiveness with the addition of the right filtration, pressure regulation, and lubrication.

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An application with high-speed pneumatic tools or process-control instrumentation requires filtering out particles down to 5 μm. Paint spraying and food-related applications require filtration down to 1 μm or less. But applying such a fine filter to the entire distribution system significantly increases initial equipment costs and maintenance in the form of filter replacement. It also drives up operating costs because a finer filter makes it more difficult for air to pass through, producing a pressure drop. And increasing air pressure to compensate raises the total cost for compressed air.

Generally, it is inadvisable to provide filtration finer than absolutely necessary because fine filter elements trap more dirt and become blocked more quickly. For an effective workaround, employ standard air-line filters as prefilters; this reduces the risk of overtaxing high-efficiency elements with coarse particles.

Oil is another contaminant found in compressed air. Oil can exist in three forms – oil/ water emulsion, aerosol, or oil vapor. While standard air-line filters can remove emulsions, only special coalescing filters can remove small particles between 1 μm and 0.01 μm. These filters are typically rated by the amount of air they can process at a given cleanliness level, normally a maximum remaining oil content of 0.01 ppm in the exit air. Flow that exceeds the rating increases not only pressure drop across the unit but also the remaining oil content. It also increases energy costs. Air-line filters mounted immediately upstream protect coalescing filters from particulate and water contamination.

Oil vapor is typically present in such minute quantities that it can be ignored, except in sensitive applications such as food and beverage processing, pharmaceuticals, and breathing air. Passing the air through an absorbing bed of activated carbon after it flows through standard and coalescing filters removes the oil vapor.

After taking all contaminants into account, consider the degree of cleanliness for each machine or part of a plant. Using the right filter in the right location minimizes energy and maintenance costs. Always determine the volume of air involved in each stage because undersized, inappropriate filters are a prime cause of high energy costs.

Point-of-use filtration In selecting point-of-use filtration, the first thing to assess is the end-use equipment itself. What does it require? Find the answer in the operating manual. Manufacturers of tools and machines powered by air specify the appropriate level of filtration, beginning with purity classes of compressed air with respect to

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particles, water, and oil. After identifying that level, the end user can specify a filter that meets the requirements. But there are important variables to keep in mind.

• Even after filtration at the main distribution point, additional contaminants may seep into the air stream via the pipework.

• Residual moisture may condense as the air moves through the distribution system.

• Harsh operating conditions, such as salt sea air, high humidity, or caustic environments, can compromise air-preparation equipment.

Countering such situations requires components with robust construction and specialized

Filter/regulator/ lubricator with shut off.

sealing materials. Some applications benefit from the addition of multistage filtration: a prefilter, a fine-particle filter, and a coalescing filter to remove oil. Using a prefilter to remove larger particles prevents the finer filter from clogging and prolongs the service life of the finer filter element. Applications benefiting from threestage filtration range from instrument air for precision fluid control to large offshore oil rigs using compressed hydrocarbon gas.

Regulating pressure All pneumatic equipment has an optimum operating pressure. Exceeding that pressure won’t yield greater productivity; it will, in fact, cause excessive wear while wasting compressed air. To use compressed air most efficiently, reduce the pressure of air leaving the compressor to the precise level the application requires.

Systems tend to operate at two pressure levels: compressed air stored in a receiver at high pressure (which optimizes filter performance and energy efficiency), and air used by actuators and other devices, usually at a pressure 10% to 20% lower. This arrangement ensures the compressor is not constantly running.

Regulators, that is, pressure-reducing valves that control pressure, have two important performance characteristics: regulation, maintaining consistent outlet pressure regardless of inlet pressure, and flow, maintaining consistent outlet pressure regardless of flow rate. The precision of regulation and required flow dictates the type and cost of the regulator.

Most regulators fall into one of four categories: general purpose, pilot operated, precision, and special purpose. Most general-purpose regulators are diaphragm types, though piston versions are used where equipment demands higher flow capacity for a given size. Adjusting manually operated knobs or handles lowers downstream pressure without actuating downstream equipment. To adjust a nonrelieving regulator to deliver lower pressure, cycle downstream equipment or use a 3/2 shutoff valve to expel excess air.

Pilot-operated regulators control outlet pressure by means of an air-pressure signal produced by a precision regulator. This means, for example, it’s possible to mount the regulator in large distribution mains but control it remotely from the shop floor.

Engineers usually use this type of control when a continuous process requires a large, steady air flow.

Precision regulators are normally used for instrumentation applications in which fast response, exact repeatability, and control of outlet pressure are necessary. These units have a limited range but superior flow and regulation characteristics. Precision regulators also can relieve up to 90% of their flow for specialized applications, such as tensioning belts, paper rolling, and balancing.

Special-purpose regulators can be based on any of the other types with application-specific modification. For example, they may be constructed of special materials like stainless steel, have high relief flows, or operate with a plunger instead of a hand wheel.

Combination filter/regulators clean air and control pressure in a compact unit, saving space and costs. Specialized filter/regulators remove fine particles of oil, offering precise regulation.

Lubricants To ensure that operating equipment performs efficiently without excessive resistance to wear, we need to introduce a lubricant, usually oil.

(Continued on page 54)

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(Continued from page 53) Aerosol oil-fog lubricators use reservoirs or bowls filled with oil, which, when generated, have relatively large oil particles that cannot rise or travel far before dropping out of the air stream. Therefore install oil-fog lubricators near the equipment they are meant to service but never below it.

There are also microfog lubricators, which atomize the oil in the bowl, creating particles less than 2 μm in size. This fog can travel upward and for long distances through complex feed lines. Microfog units can also ensure proportionate distribution through numerous lubrication outlets, making it ideal for multiple valve-control circuits. Only about 10% of the oil in a microfog system becomes an aerosol, so it works well in applications requiring only small amounts of lubricant. By adjusting the drip rate, oil delivery can be raised to approach that of an oil-fog lubricator.

One other type of lubricator is a positive-displacement injection pump. It does not continuously deliver lubricant like aerosol lubricators but instead injects the same amount of lubricant every cycle. This type is often used on conveyor chains where several injectors can be joined together on a manifold to treat different points at the same frequency.

Most valves and cylinders powered by pneumatics are prelubricated and in most applications do not require additional lubrication during their service life. Once they reach the end of their lubrication life, nonrepairable cylinders must be replaced. Other components can be repaired, but technicians must apply new grease before they are put back into service. In addition, contaminated air gradually compromises the original grease lubricant and shortens the seal life.

Lubricated air prolongs the life and performance of prelubricated components.

Applications that have high cycles, operate at high speeds, or use large diameter bearings can generate heat that speeds up the deterioration of internal lubrication. Lubricated air is also essential for equipment that is not prelubricated, for example, pneumatic hand tools such as screwdrivers.

Lubricated air extends cylinder life, but it also washes out the original lubrication. So once lubricated air is introduced, it must always be used. The amount of oil for sufficient lubrication varies with each pneumatic device, so it is important to follow equipment manufacturers’ recommendations. From regular inspections and servicing, technicians can determine the optimum setting and adjust the amount delivered.

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Safety Compressed air is powerful, so it is important to have safety features built-in to the pneumatic system to protect equipment and personnel.

The first safety consideration is overpressure protection. Components in pneumatic systems often have a pressure rating lower than what is generated by the compressor. If for some reason the regulators do not maintain safe working pressure (SWP), downstream components exposed to excess pressure can malfunction or fail.

The most common overpressure protection is a relief valve. This device holds system pressure at a constant level at or below the stated SWP. Relief

Pressure sensor.

valves should operate only when the system exceeds regulated pressure, so they need to be set to a pressure higher than that for the regulator.

Frequently, relief valves are situated too close to the system operating pressure, causing the relief valve to vent air during normal operation.

The relief device must also be sized to match or exceed flow through the parts of the systems it protects, without system pressure rising above the acceptable overpressure level.

Finally, consider start-up. Loading during start-up can cause unnecessary wear on moving

parts, and sudden movement can injure personnel. Soft-start valves prevent such problems. They let air gradually bypass from a compressor to the pneumatic system. Adjusting the valve controls the rate of pressure buildup. The valves usually have a spring-operated internal poppet design, set to open, or “snap,” when pressure reaches between 40% and 70% of full-line pressure. It is more economical to set these devices near the equipment they are intended to protect rather than fit a larger valve to the whole distribution system.

We’ve mentioned many of the challenges to proper air preparation presented by such variables as harsh environments. Numerous industrial processes require extremely high pressures, and these must be carefully monitored.

When faced with such conditions be aware of the various kinds of sensors capable of detecting pressure and switches that can open or close a connection based on the pressure level. Options include simple but effective electromechanical pressure switches, electronic pressure switches with few moving parts and offline programming, and pressure transducers or transmitters that convert pressure into an analog electrical signal.

A recent study from Research and Markets estimates that the smart pneumatics market will grow by nearly 7% between now and 2026.

This growth depends on equipment effectiveness, which is itself determined by IIoT factors.

Predictive maintenance will save up to 12% over scheduled repairs, reducing overall maintenance costs up to 30% and eliminating breakdowns up to 70%. For fluid power systems, says the report, this “means a whole new level of condition and remote monitoring.” In short, compressed air generation, properly installed and maintained, can deliver years of trouble-reduced operations. 

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A DV E RT I S E R I N D E X Company.............................................................................. Page............................... Phone.........................................................................................................................................Website Ace Controls Inc..........................................................................9......................................... 800-521-3320...................................................................................................................www.acecontrols.com Aggressive Hydraulics.................................................................Back Cover, 50.................. 866-406-4100.................................................................................................. www.AggressiveHydraulics.com Allegheny York LLC......................................................................14....................................... 717-266-6617...............................................................................................................www.AlleghenyYork.com Bimba Manufacturing Company.................................................7......................................... 800-442-4622............................................................................................................................ www.bimba.com DELTA Computer Systems Inc....................................................16....................................... 1-360-254-8688........................................................................................................................deltamotion.com EUFMC 2021.................................................................................42.......................................................................................................................................................................................... www.eufmc.com Festo Corp....................................................................................Inside Back........................ 1-800-993-3786............................................................................................................................. www.festo.us Flange Lock..................................................................................23....................................... 203-861-9400..................................................................................................................... www.flangelock.com Heinrichs USA..............................................................................21....................................... 859-371-4999................................................................................................................ www.heinrichs-usa.com Hydraulex......................................................................................19, 50................................. 1-800-323-8416.................................................................................................................. www.hydraulex.com Hydraulics International Inc........................................................24, 50................................. 818-407-3400....................................................................................................................... www.hiipumps.com Hydraulics, Inc..............................................................................10....................................... 817-923-1965................................................................................................................ www.hydraulicsinc.com Inserta Products...........................................................................5, 50................................... 215-643-0192 .......................................................................................................................... www.inserta.com Jason Industrial...........................................................................6......................................... 630-752-0600.............................................................................................................www.JasonIndustrial.com La-Man Corp.................................................................................15, 50................................. 800-348-2463 ........................................................................................................................... www.laman.com Main Manufacturing Products Inc..............................................24, 51................................. 1-800-521-7918..............................................................................................................www.mainmfg.com/fpj MOCAP INC..................................................................................10....................................... 800-633-6775 .......................................................................................................................... www.mocap.com MP Filtri USA Inc..........................................................................5, 21, 46............................. 215-529-1300.............................................................................................................. WWW.MPFILTRUSA.COM NR Pneumatics USA....................................................................46....................................... 718-522-5575............................................................................................................... www.nrpneumatics.com Oil-Rite Corp.................................................................................51....................................... 920-682-6173............................................................................................................................. www.oilrite.com Peninsular Cylinder Co. Inc.........................................................49....................................... 1-800-526-7968.................................................................................................. www.peninsularcylinders.com Pressure Components Inc...........................................................51....................................... 440-349-4020...................................................................................................www.pressurecomponents.com RAM Industries.............................................................................47....................................... 877-799-1005............................................................................................................... www.ramindustries.com SPIR STAR Ltd..............................................................................9......................................... 1-800-890-7827...................................................................................................................... www.spirstar.com Starcyl Cylinders Corp.................................................................1......................................... 1-877-782-7295....................................................................................................................... www.Starcyl.com Sunfab Hydraulics Inc..................................................................43....................................... +1 (704) 509-6435............................................................................................................ www.sunfab.com/us Super Swivels...............................................................................45, 51................................. 1-763-784-5531.............................................................................................................www.superswivels.com Tahoma Engineered Solutions, Inc.............................................15....................................... 419-496-0964, ext. 203...................................................................... www.TahomaEngineeredSolutions.com Targeted Display Advertising......................................................47....................................... 610-923-0380.................................................................fluidpowerjournal.com/targeted-display-advertising/ Tele Radio LLC..............................................................................13....................................... 866-629-0780.................................................................................................................WWW.TELERADIO.COM Texcel............................................................................................3......................................... 1-800-231-7116.............................................................................................................. www.texcelrubber.com Ultra Clean Technologies.............................................................Inside Front....................... 800-791-9111...............................................................................................................www.ultracleantech.com WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

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