Fluid Power Journal May/June 2010

product spotlight on proportional & servo valves

May/June 2010

IFPS

Certification:

Alexandria Technical College

&

CFD Aided Design Pressure Sensors

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contents May/June 2010

•

Volume 17

•

Issue 5

Features

10 13 14 18 22

Testing and Qualification of Pressure Sensors

for Use in Hydrogen Applications

By Karmjit S. Sidhu, Vice President, Business Development, American Sensor Technologies

Energy Challenge: The Hydraulic Solution

By Dan Helgerson Cascade Steel Rolling Mills, Inc., dhelgerson@schn.com

28 30 Units of Measurement

By Daniel Pascoe, General Manager, Vacuforce, Inc.

The Looming Efficiency Imperative

By Brendan Casey

Alexandria Technical College:

IFPS Certification Sets a Standard for Education

By Futek Advanced Sensor Technology, Inc.

departments

18

CFD Aided Design of Valves and Pumps

By Sam Lowry, PhD, President, and Zhemin Wu, PhD, Research Engineer, Simerics, Inc.

The Demand for High Speed Efficient Solutions: USB Technology

IFPS Certification Success Story:

21

4 6 7 8 9 15 20 21 24 32 38 39

Notable Words All About Air Figure It Out IFPS Time Capsule Math Teaser Web Marketplace Calendar of Events Product Review Product Spotlight Association News Professional Development Classifieds

Official Publication of The International Fluid Power Society

Request more information at www.fluidpowerjournal.com

NotableWords

By David E. Thun, Power Systems

Publisher Innovative Designs & Publishing, Inc. 3245 Freemansburg Avenue, Palmer, PA 18045-7118 Tel: 800-730-5904 or 610-923-0380 Fax: 610-923-0390 | Email: AskUs@ifps.org www.FluidPowerJournal.com Associate Publisher Marc Mitchell Art Director Quynh Vo Editor Kristine Coblitz VP Operations Lisa Prass Account Executive Bob McKinney Accounting Donna Bachman, Debbie Clune OPERATIONS ASSISTANT Tammy DeLong Circulation Manager Andrea Karges

International Fluid Power Society 1930 East Marlton Pike, Suite A-2, Cherry Hill, NJ 08003-2141 Tel: 856-489-8983 Fax: 856-424-9248 | Email: AskUs@ifps.org www.ifps.org

2010 Board of Directors

Was Last Year Really So Bad For Our Business?

All

I heard last year was how bad business was in our industry. I know it scared me! Let’s face it--we didn’t have a lot of fun. Many of us had to eliminate positions, find new customers, restructure our companies, deal with customers that went bankrupt and/or had difficulty paying their bills, and watch expenses like a hawk. Perhaps we should look at these changes and challenges as a blessing, however, and perhaps we should have been making substantive changes in our businesses prior to the economic downturn.

If we made significant changes, I think we now have companies that are competitively structured for the future. Last year, many of us spent time visiting and talking to customers whose markets imploded. We worked with these customers on new technologies, new applications, and new products. Because of the business slowdown, our customers had time to prototype new products and bring them to market. Most importantly, by putting more time into visiting with customers, we developed new friendships and resources, and we increased customer loyalty by being there when they needed new products and applications to strengthen their businesses. These actions will continue to help us grow our businesses in the future because I believe customer loyalty always shows up on the bottom line.

We were also able to spend more time with our employees. We probably all found employees at our companies who had talents and abilities that had not previously been identified. And to our employees’ credit, they had to be proficient in many jobs because there were fewer of them in the company. Because of restructuring our businesses, I am quite certain that we became more efficient in our operations. We hopefully were able to eliminate inefficient and perhaps worthless procedures, which translated into lower costs.

As the business economy improves, don’t go back to old ways. Keep looking for additional worthless procedures to eliminate. Continue to be more efficient. Make developing new customer relationships and increasing customer loyalty part of your everyday operations. Continue to spend time communicating with your employees and developing their talents; employees are tools to help grow your business every year.

And don’t forget to reward these employees through appreciation memos, breaks, and lunches, or through other appropriate actions including incentives and bonuses.

We all talk about having to be competitive in the global market. With our renewed companies, we should be stronger, leaner competitors. Remember, we are and will be competing with countries that are hungry for success, and they are not going to run out of people and ideas for a long time. Maybe 2009 is what we needed for the future.

President & Chairperson Rickey L. Rodeffer, CFPS, CFPMIH, CFPMT, CFPAI The Boeing Company Immediate Past President Robert Yund, CFPAI, CFPIHT, CFPS, CFPCC | Hennepin Technical College First Vice President Jon Jensen, CFPAI, CFPPS, CFPECS | SMC Corporation of America Vice President Education James F. Simpson, CFPS, CFPMM, CFPAI Nusim Assoc Fluid Power Consultant Treasurer Patrick J. Maluso, CFPMHM, CFPS, CFPAI | Western Hydrostatics, Inc. Vice President Membership & Chapter Support Leo C. Henry, Jr., CFPMHM, CFPCC, CFPAI | Altec Industries, Inc. Vice President Certification Wayne C. Farley, CFPMMH, CFPAI | American Electric Power Vice President Marketing and Public Relations Mark Perry, CFPHS | Fitzsimmons Hydraulics

Directors-at-Large

George Bufink, CFPAI, CFPMMH | American Electric Power Dennis Crouch, CFPCC, CFPHS, CFPIHT, CFPAI General Motors (retired) Mike Anderson, CFPS | Motion Industries Tom Blansett, CFPS | Eaton Corporation Justin Sergeant, CFPS | Open Loop Energy, Inc. Bismarck (Bill) Castaneda, CFPHS | Automation Tech, Inc. Jeremiah Johnson, CFPHS | Caterpillar, Inc. Doug Daniels, CFPHS, CFPAI | Mohawk College Jean Knowles, CFPS, CFPE | Spencer Fluid Power, Inc. Marti Wendel, CFPS, CFPE | The Paquin Company, Inc. L. David Ruffus, CFPAI, CFPMHM, CFPMHT | Georgia Power Company Richard Bullers, CFPPS | SMC Corporation of America

Honorary Directors

Robert Firth, John Groot, CFPPS Raymond Hanley, CFPE/AI-Emeritus Robert Sheaf, CFPAI, CFPE, CFPMM, CFPMT, CFPMIT, CFPMMH, CFPMIH, CFPECS

IFPS Staff

Donna Pollander, Executive Director Sue Tesauro, Certification Manager Adele Kayser, Communications Manager Sue Dyson, Membership Coordinator Connie Graham, Certification Coordinator Diane McMahon, Certification Coordinator Beth Borodziuk, Administrative Assistant Nick Pollander, Certification Assistant Diane McMahon, Bookkeeper Fluid Power Journal (ISSN# 1073-7898) is the official publication of the International Fluid Power Society published bi-monthly with four supplemental issues, including a Systems Integrator Directory, 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. POSTMASTER: Please send Address Corrections to Fluid Power Journal, PO Box 2548, Orlando, FL 32802-9830

4 | May/June 2010

www.ifps.org | www.fluidpowerjournal.com

ALA Industries, Ltd. The Yuken Master Distributor

Yuken instrumental in booming, "Green" recycling industry A crushing problem of uncrushed cardboard at local supermarkets was the spark that fired Harmony Enterprises. Concern for the resulting air pollution from cardboard incineration led to the creation of Harmony’s first Low-Profile Baler in 1970. Today, Harmony is honored to contribute to society by producing recycling equipment that protects the environment and ensures a more beautiful world for future generations.

Yuken’s quality, reliability, and economical pricing is helping Harmony achieve these advances while remaining competitive. Punctual distribution, customer service, and technical and sales support are absolutely required from their vendors. ALA and Yuken provide this by maintaining two months of buffer stock at all times and staffing an experienced technical team. Harmony Enterprises has recently introduced a tire compactor controlled by Yuken soft-shift solenoid valves. This machine is advancing an entire new way to reduce space in land fills. Yuken is very proud to partner with such an innovative, environmentally friendly company.

International Baler has been a leader in design and manufacture of commercial and industrial baling and recycling equipment since 1954.

Since quality, reliability, and durability are most important to International Baler Corp. when they’re shopping for components, they look to Yuken for valves with those same key features. Not only are the Yuken DSG and DSHG valves tough against contamination and work with nearly no noise, they offer high pressure, high flow, and low pressure drop. For balers designed and engineered specifically with safety, dependability, and ease of operation in mind, Yuken products are the perfect match.

By offering high quality valves with second-to-none reliability and readily available on-hand stock, Yuken makes this supplier-OEM relationship a strong one.

1150 Southpoint Drive Suite D

Request more information at www.fluidpowerjournal.com

Phone: 877-419-8536 Fax:219-477-4194 E-mail: joemarshall@yuken-usa.com

AllAboutAir

Thomas W. Kreher, CFPPT | Applied Pneumatic Controls, Inc. | OIL SMOKE® www.applied-pneumatic.com

Pneumatic Filter Flow Factors

G

enerally we agree that keeping pressure drop to a minimum is a good thing. As air is compressed, it costs more in electrical energy to compress it to a higher level.

Assume we desire or require 90-psig minimum compressed air pressure at the point of use. If we have a cascade of items causing pressure drop before we use the air, it would be necessary to “over-compress.” A pressure drop in the plumbing that conveys the compressed air is inevitable, but the amount of this “transportation expense” can be minimal while often it is miserable. Each and every device the compressed air passes through en-route to the point of use will cause some additional pressure drop. It is often stated that the air compressor may be the single largest user of electrical energy in a typical manufacturing plant. Still a very bright Mill Wright in a plant with 600-hp compressors recently said, “We don’t do much with compressed air compared to hydraulics.” Because replacing a hydraulic pump is time consuming and a big-ticket item, it creates an illusion. The compressed air and related devices seem much less consequential or costly.

If the proposed Cap and Trade legislation is passed and results in an energy usage tax, the front office may be the first to realize how much is spent on compressed air. Common sense will hopefully lead us to evaluate many items in compressed air systems that are taken for granted.

One item that is rarely questioned is the common pneumatic filter often used in a three-piece combination with a regulator and lubricator known as a “trio.” The purpose of the filter is to hold back small particles and remove condensate to protect items down stream from abrasive trash, excess water, and sludge with a manual or automatic drain. Removing these contaminants is a good thing when it reduces wear and failure of other devices or actuators using the cleaner air. However, each filter will cause a pressure drop. Some attention to detail and forethought can make that a reasonable trade-off of unnecessary expense.

1. The maximum flow data in catalogs is commonly based upon 90 or 100 psig with a 5-psid pressure drop.

2. Other data is presented in graphs that show curves exceeding 6-psid drop.

3. When the pressure drop caused by supply plumbing, regulators, ball valves, lockout valves, etc. decreases the supply, the filter pressure drop will increase.

Assume for the minute that virtually all of the compressed air in a plant will pass through one or more filters before reaching point of use. Subsequently, with astute selection of filter size and micron rating, 100% of the air may have an average 3-psid pressure loss from filters alone. The Womack Fluid

Request more information at www.fluidpowerjournal.com

6 | May/June 2010

Power Data Book shows 0.003 horsepower per scfm required for the additional pressure to maintain 90 at point of use. For a 600-hp system, this is only a few thousand dollars a year. Combined with other sources of pressure drop, the total loss can be hard to justify.

To use compressed air wisely when dealing with the general-purpose air filters, please consider these steps: 1. Check the air supply to see if it is already filtered within 100 feet.

2. Choose the largest filter micron rating that would be suitable. If this filter is primarily for condensate, take the filter element out.

3. Chose a body and port size that minimizes pressure drop. One psid is plenty. If an intermediate 3/8" body size may work, 1/2" will work better.

The time has come to eliminate leaks, losses, overpressure, and undersized components in our use of compressed air. One discontinued chart shows that in the same 1/2" basic filter body size, one unit with 1/4" ports and 5-micron filter element at 90 psig and 50 scfm has a pressure drop of 4 psid. The same body with 3/4" ports and a 75 micron rated element has a pressure drop of 0.3 (3/10) psid. This may be an extreme case but the kind of advantage worth looking for.

Request more information at www.fluidpowerjournal.com

www.ifps.org | www.fluidpowerjournal.com

Robert J. Sheaf, Jr. | CFPAI, CFPAJPPCC, CFPAJPP, CFPE, CFPMIH, CFPMIP, CFPMMH, CFPMM, CFPMT, CFPS, CFPCC | CFC-Solar, Inc., www.cfc-solar.com, rjsheaf@cfc-solar.com

New Problem:

Molding Press with Intensifier An aerospace subcontractor used an old modified upward-acting rubber press to mold and cure a rubber-type coating to a part used in the manufacture of the B-1 bomber. The existing hydraulic system of the press was not able to reach the pressures required to keep the mold closed when the material was curing. To increase the pressure, a 4:1 Modern Controls oil-over-oil intensifier was added to the circuit (see the basic schematic). They also added a bypass check around the intensifier to allow quick closure until pressure was needed, and then the intensifier completed the cycle.

The unit worked well for about four months, and then the intensifier failed. On inspection, broken parts were found inside. The maintenance department secured and replaced the unit with a new one, but this unit only lasted four weeks and then failed.

Maintenance workers thought the pump pressure may have been increased, causing the intensifier to fail. (The pump was capable of 1500 psi, and that could have resulted in 6000 psi exceeding the 4000 psi intensifier rating.) They had verified 700 psi at the pump was the correct setting needed from the compensator to result in 2800 psi needed at the mold. They found the safety relief was set at 3500 psi, so they reset it to 850 psi.

The third replacement intensifier failed in six weeks.

Any idea what could be causing the problem?

Answers and comments may be submitted to Robert Sheaf at rjsheaf@cfc-solar.com.

FigureItOut

Previous Problem: Rod Gland Failure Problem on a Molding Press (from the Off-Highway Directory 2010 issue) A manufacturer in Central Ohio built a molding press to use in their facility. They needed about 70,000 lbs of force to keep the mold from parting while the molded part cured.

They had a hydraulic power unit that provided enough flow and could develop 1200 psi.

The unit had usable mounted valves, so just a cylinder and a pilot-operated check were needed. They wanted to lock the cylinder in the retracted upper position while they trimmed and ground the finished mold to then re-strike the mold, driving steel-threaded inserts into various locations.

The design engineer shopped around for a cylinder and pilot-operated check valve. The system was installed, and commissioning was started. Operators found the cylinder to be very jerky on the down-stroke, stopping and starting several times. It was suggested that they install a back-pressure valve that would cause enough back pressure, keep the pilotoperated check open, but not reduce the cylinder closing speed. They purchased a flow control and adjusted it until the bumping problem was eliminated. (See the circuit.)

After two weeks of production, the cylinder rod gland failed and dumped hydraulic oil over the mold. The cylinder came crashing down, almost injuring one of the operators.

The cylinder’s maximum operating pressure was confirmed to be greater than the maximum system pressure of 1200 psi. In fact, the cylinder was rated up to 2000 psi. The manufacturer was advised to make sure the back pressure flow control valve was opened as far as possible so as not to cause meter-out rod intensification. (This is probably one of the few places where a flow control is used to create back pressure, only since all the back pressure bleeds off when the cylinder stops extending, giving maximum tonnage during the pressing stage.) Any idea why the rod gland continued to fail every two to three weeks?

Solution:

The problem with the cylinder was caused by the incorrect pilot ratio of the pilot-to-open check valve. Workers just purchased a stock valve from their local hydraulic distributor and never considered checking the valve's pilot ratio. When in the retracted position, the 14,000-lb mold caused about 935 psi of pressure trapped in the rod side of the cylinder. Using a 4:1 ratio check valve seemed more than sufficient. However, as the pressure starts to buildup on the cap side of the cylinder for extention, this pressure in the cap times the cap area creates a force that acts on the rod side. Divide this force by the rod area and add this PSI to the pressure caused by the load. Now the PSI needed to open the PO check increases.

There is a formula that I use that will give you the needed pilot ratio to keep this pressure buildup from exceeding the pressure rating of the cylinder:

Minimum ratio needed = maximum operating PSI allowed x cap area (rod area x maximum allowed PSI) – Load When the values are plugged in, a minimum pilot ratio of 6.25:1 is needed to keep the buildup of rod pressure from exceeding 2000 psi.

A 4:1 ratio allows this pressure to build up to approximately 5600 psi, way beyond the cylinder’s maximum operating pressure. www.ifps.org | www.fluidpowerjournal.com

May/June 2010 | 7

C elebrating 50Years

The International Fluid Power Society

IFPS Time Capsule

In 2010, the International Fluid Power Society (IFPS) will celebrate its 50th anniversary as the organization for fluid power and motion control professionals worldwide. In this column, which will run in every issue through 2010, we’ll take a look back at some of the most significant achievements and milestones in the Society’s history. Please participate in this column by submitting your own memories and photos to Kristine Coblitz at kcoblitz@fluidpowerjournal.com or Donna Pollander at dpollander@ifps.org.

A History of the IFPS Certification Program 1980: The Fluid Power Specialist certification program is developed and released.

2000: Mobile Hydraulic Technician manual and certification are written and released.

1987-1989: Ray Hanley, CFPE, AI, Emeritus, with the financial support of Char-Lynn Company, begins an FPS certification revival.

2004: The Fluid Power Conductor and Connector certification test is released.

1991: The Mechanic certification test is released and divided into two stages: Mechanic I and Mechanic II, featuring separate tests for hydraulics and pneumatics.

2007: The Raymond Hanley Certification Endowment Fund is estab-

1992: Three fluid power occupations are officially recognized

by the U.S. Department of Labor in its Dictionary of Occupational Titles (D.O.T.).

1993:

Pneumatic Mechanic manual and certification test are released. The Engineer certification is developed and has since transformed into today’s CFPE (Certified Fluid Power Engineer) certification.

1994: The Mobile Hydraulic Mechanic and Pneumatic Mechanic certification tests are released.

1996: The FPS Web site is designed and launched by John Groot, CFPPS, IFPS past president and life member.

1998-1999:

The Specialist certification is split into separate certification tests for Hydraulic Specialist and Pneumatic Specialist; the Hydraulic Specialist test and Job Performance Test are revamped and re-released.

8 | May/June 2010

lished for technology training for IFPS Accredited Instructors.

2009: Mechatronics certification groundwork begins.

2009-2010: The Electronic Controls Specialist certification is released.

2010: The Mobile Electronic Controls and Industrial Electronic Controls certifications begin development.

“My tenure as president of the IFPS was during a difficult and trying period. Our bank account went negative, controversy bubbled up from chapters, and if it weren’t for Paul Prass, the director at the time, and his convictions, the Society would not have made it. He assembled a group of supporters and personally shouldered the financial responsibility, even though he couldn’t afford it, and through his diligence, the IFPS is what it is today.”

- Frank Garner, 1997-98 IFPS President www.ifps.org | www.fluidpowerjournal.com

MathTeasers

with Professor P.V. Btfsplk

This Issue

Solution: Pneumatic Receiver

(From March/April 2010 Issue)

A compressed air receiver has an internal volume of 6000 ft3 and it is inflated to a pressure of 135 psig at a temperature of 60°F. Later the temperature is increased by 30°F. Please calculate the new pressure of air in the receiver.

P1/P2 = T1/T2 = P1 =135 psig = 135 +14.7 = 149.7 psia T1 = 60°F =460-R+ 600-F = 5200-R T2 = 5200-R + 30°F = 550°-R P2 = P1(T2/T1) = 149.7 (550/520) = 158.3 psia

The final pressure is = 158.3 psia -14.7 = 143.6 psig Winner:

Illustration: John Spisak

Jason Moore CFPHS Parker Hannifin Ravenna, OH

Answered Correctly

Problem: Expansion Tank An expansion tank in a heated system is an oil barrel with an internal diameter of 24 inches and a height of 40 inches. When half filled with water, the pressure equals 30 psig. If the water level falls by 8 inches, what will the pressure of air in the barrel be?

Ernie Parker CFPAI, CFPMM, CFPMT, CFPS, CFPCC Hennepin Technical College Eden Prairie, MN Michael Petroff CFPS Coon Rapids, MN Harry Pawluk, Jr. CFPS, Hanco, Inc. Lawrence, PA

Joseph Entwistle CFPE Hydro Air Hughes, LLC North Haven, CT

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

David Petersen CFPHS, Brand Hydraulics Omaha, NE

Curt Larsen Hennepin Technical College

Allan Pavalko CFPPS SMC Corporation Richfield, OH Tri Nguyen CFPS Plymouth, MN Adrian Gutierrez Parker Hannifin

Dean Curlee Livingston & Haven Frank Stilwagner CFPE, CFPMM, CFPS, CFPAI Catching Fluid Power Bolingbrook, IL Jeff Curlee CFPPS Production Systems, Inc. High Point, NC

Jon Jensen CFPPS, CFPAI, CFPECS SMC Corporation of America Naperville, IL Patrick Harris CFPS Hennepin Technical College Eden Prairie, MN Parker Cook CFPHS Parker Hannifin Corporation Wickliffe, OH Jeffrey Greene CFPHS The Raymond Corporation Greene, NY

4C

The teaser is posted on the IFPS Web site (www.ifps.org) and also printed in the Fluid Power Journal. Submit your information via the Web site, or fax it to 856-424-9248 attn: Donna Pollander. Anyone who submits Marzocchis MT 2008 PUB: Fluid Power Journal LIVE: 7.125 x 4.375” TRIM: 7.625 x 4.875” BLEED: N/A INK: the correct answer before the deadline date will have his/her name printed in the Society Page newsletter and in Fluid Power Journal. The winner will also be entered into a drawing for a special gift.

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Both series offer exceptional versatility. ALP/GHP Modular Pumps, which are readily available at our U.S. facility, offer total interconnectivity for limitless possibilities. Our ALPC/GHPC Short Multiple Pumps are made-to-order to match all your OEM applications and are economic in both size and cost to you.

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www.ifps.org | www.fluidpowerjournal.com Marzocchis MT-HalfPg_FPJ.indd 1

May/June 2010 2/2/09 8:02:39 PM| 9

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By Karmjit S. Sidhu, Vice President, Business Development, American Sensor Technologies the use of hydrogen increases in the processes associated with the petroleum industry, material handling, stand-by power generation, and surface transportation, new certifications and qualifications are being mandated for safe use and storage of hydrogen.

Hydrogen, as the lightest element in the universe, must be handled with care, with steps taken to avoid fatality as a result of permeation and embrittlement. For safety, several industries and markets utilizing hydrogen in their processes have mandated certain testing and approvals before components, such as sensors, tubing, storage tanks, valves, regulators and fuel cells, can be used on a specific piece of equipment.

In the automotive and surface transportation applications, pressure sensors used as components for hydrogen are covered under European Integrated Hydrogen Project (EIHP), Society of Automotive Engineers (SAE) and Japanese Automotive Research Institute (JARI) mandates. For industrial applications, Underwriter Lab (UL), Canadian Standards Association (CSA), and Technischer Ăœberwachungsverein (TUV) dictate the standards on national safety codes such as National Electrical Code (NEC), National Fire Protection Association (NFPA), and Canadian Electrical Codes (CEC). UL, CSA, and TUV can also perform the necessary testing and certification process for all markets.

Automotive and Surface Transportation Using Hydrogen Fuel Europe has been the front-runner in regards to the use of hydrogen as a fuel carrier for cars, buses, and lights trucks. EIHP was established to help promote hydrogen technology and applications to increase the competitiveness of European companies. Since then, both SAE and JARI have adapted the EIHP practice for hydrogen safe use and storage. The first phase of EIHP included the drafting of safety-related specifications and requirements of hydrogen systems and components. Pressure sensors for 20 Bar (290 psi), 448 Bar (6500 psi) and 900 Bar (13,000 psi) systems must be tested to ECE (Draft) Regulation TRANS/WP.29/GRPE/2004/3 dated 31 October 2003 (EIHP Draft Rev. 12b) and TRANS/WP.29/GRPE/2004/3/Add.1 dated 23 March 2004 for on-board storage systems of compressed hydrogen fuel in vehicles. EIHP II is underway, with the draft becoming a permanent mandate by 24 Feb 2011. After this date, national authorities will not allow any new component into service that is not clearly marked that it has met the EIHP test and qualifications requirements.

Testing and qualifications for safe hydrogen service can be conducted by TUV SUD Automotive GmbH. The tests are performed and witnessed by TUV as shown in Table 1. Once testing is completed and no failures are found, TUV will issue a Type approval Reference Number that must be included on the label of the pressure sensor prior to shipment.

Hydrogen Forklifts

Table. 1 Tests Conducted to meet EIHP No

Test

ECE Reverence Annex 8

1

Hydrogen Compatibility

B1

2

Aging Test

B2

3

Corrosion Resistance Test

B4

4

Endurance Test

B5

5

Pressure Cycle Test

B6

6

External Leakage Test

B8

7

Hydraulic Strength

8

Isolation Resistance

9

EMC/RFI Compatibility

Media Compatibility of Hydrogen

The hydrogen forklift market is expanding and will replace lead-acid batterPart of compliance to EIHP, TUV, UL, and CSA standards involves media ies due to productivity and cost. Fuel cell forklifts offer many benefits over the compatibility because of the effects of hydrogen permeability and embrittlement. traditional lead-acid batteries such as: The pressure sensor manufacturer needs to select the correct, cost-effective • Environmental benefit: Hydrogen fuel cell systems do not emit pollutants. sensor material to ensure long, trouble-free service in hydrogen. Most pressure For forklifts used indoors, this helps create a cleaner and healthier working sensors offer stainless steel wetted parts. However, it should be noted, that environment. not all steels are compatible with hydrogen. High-strength stainless martensitic • Disposal of lead-acid batteries would be eliminated, creating a cleaner environment.

• Longer life: A hydrogen fuel cell pack can last 10 to 12 years versus up to 5 years for a lead-acid battery. Maintenance Fig. 1 Cross section of oil-filled sensor with thin costs are also expected to be lower for the fuel cell packs.

• Refueling is faster than charging: The hydrogen fueling stasensing membrane with hydrogen leak path tion is easy to operate. Filling the fuel cell pack, typically 3000 to 5000 psi, takes only two to five minutes. Changing a battery can take seven minutes, and recharging and cooling it takes approximately 15 to 17 hours. A factory running 24 Pressure hours can reduce the number of required forklifts because sensing cell Fill fluid they do not have a wait time for battery charges.

• Extended run-time between fills: A completely filled hydrogen fuel cell forklift can run for about 18 hours while the Glass to metal Process plant is in full production. A battery-powered forklift runs for feedthrough approximately four to six hours before the battery must be recharged.

• Consistent and better power: As a lead-acid battery loses + power, the forklift will slow down. There is no slowdown Silicon with the hydrogen fuel cell. The forklift operates at 100% H pressure 2 power all the time, and drivers can refill the unit whenever they want. chip + H For certifications, UL standard UL2267 or CSA HPIT 1, subject to end-user requirements, are used to certify the fuel cell truck.

Pressure sensors used on the hydrogen tank and fuel cells are Hydrogen also tested for ordinary or hazardous location, subject to the envibubbles ronment where the truck will operate. If the pressure sensors are already approved from a reputable supplier with 316L stainless Stainless steel steel wetted parts, some of the testing can be waived due to prior diaphragm approvals.

H

www.ifps.org | www.fluidpowerjournal.com

May/June 2010 | 11

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The recovery of oil from bituminous sands and deep below the ground poses a challenge for pressure sensors due to the severe erosion of metals associated in the presence of temperature, Hydrogen (H2) and Hydrogen Sulfide (H2S).

As the world runs out of low sulfur oil, oil companies are racing to develop new sources for petroleum, which is not easy to process. Here, the need for better corrosion-resistance materials and extended testing is required to withstand material erosion in the presence of H2-H2S. Materials with high levels of cobalt, nickel, and chromium with small quantities of molybdenum, aluminum, and tungsten are being developed to minimize erosion. While the National Association of Corrosion Engineers (NACE) specifies materials that can be used for H2S service, there is no mention of H2-H2S service. While UL, CSA, and TUV can test the pressure sensors for area classifications such as Class 1, Zone 0 & 1 Groups B, C and D, the effects of material loss due to erosion must be taken into account based on the material composition, operating temperature, and concentration of H2 and H2S.

ication

A

H2-H2S Service in the Oil & Gas Industry

Q

lif a u

Te s t i n g a nd

steels such as 17-4PH and 15-5PH should be avoided since they are highly embrittle in hydrogen. Austenitic steels such as 316L with low carbon content are well suited against hydrogen embrittlement. The molybdenum and high nickel content, together with high stacking fault energy, makes 316L the ideal cost effective material for pressure sensors.

Another failure mechanism in pressure sensors is permeation as a result of this sensing membrane. Oil-filled pressure sensors that employ a very thin isolation diaphragm, typically 0.025 mm (0.001”) in thickness, will allow hydrogen + ions to escape through it. As thickness increases, to say 0.18 mm (0.007”), the permeation tends to stop, subject to the operating temperature.

Fig. 1 shows hydrogen permeation through thin sensor membrane.

n in H e g ydro

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By Dan Helgerson, CFPAI, CFPAJPPCC, CFPMT, CFPCC, CFPS, Cascade Steel Rolling Mills, Inc., dhelgerson@schn.com

Energy Challenge: The Hydraulic Solution And the winner is…

You had your chance. But now you will have to endure listening to me explain how I would achieve the most efficient hydraulic system. I gave my solution to the pneumatic challenge in the previous article.

A quick recap for those who may be new to the Journal: A 300,000-pound load has to be moved 8 feet horizontally in 10 seconds by a 6"x 4" x 120" cylinder. The load is positioned 2 feet away from the retracted cylinder. The cylinder rod must extend 24" in one second before it contacts the load and then slide the load sideways covering the remaining 96" in 8 seconds. The cylinder then immediately retracts fully in ten seconds. We were given a coefficient of friction of 0.25, a tank line pressure of 100 psig, and an assumed system efficiency of 85%. There is a dwell time of 2 minutes before the system repeats. The system operates 12 hours per day and for 6 days per week. (Fig. 1) In a subsequent article, I gave you some calculations including the frictional load, the acceleration load, the maximum flow rate, and the maximum pressure.

We looked at this information and showed that it would take 292 kW, 202 gpm at 2816 psi to do the job.

But then I had you look at the average power consumption over the 140 seconds of cycle time. We took one-second snapshots of the power usage, and I gave you the average power consumption of 8.84 kW. All you had to do was come up with a circuit that would approach that number. And remember, the goal is to find the most energy-efficient system, not the simplest or the cheapest.

Now, get out your calculator and let’s do some math!

I hope that most of you have immediately concluded that, because of the relatively long dwell time, this system cries out for some type of accumulator.

By finding the average flow over the entire cycle time, we might be able to have a constant power draw storing the energy in an accumulator during the dwell time. So, who wants to tell us how to find the average flow rate? I want someone who has not participated before. How about one of you mobile guys? Ok, you with the John Deere cap, what do we do? Right! We take the total cylinder volume, both extending and retracting, and divide it by the cycle time. And what did you find? A total volume of 22.85 gallons divided by a cycle time of 140 seconds (2.33 minutes) gives an average flow rate of 9.81 gpm. So, if we take our average flow and charge a very large or a properly weighted accumulator at 2816 psi, we will need [(9.81 x 2,816) / 1714]/ 0.85 or 18.96 hp, which is 14.14 kW. This is certainly a lot better than the 292 kW, but I think we can do better.

I am going to suggest three things that will dramatically reduce the kW requirements of the system. First of all, I will use a regenerative system for the first

Figure 1

www.ifps.org | www.fluidpowerjournal.com

Figure 2 two seconds as the cylinder rod moves toward the load. This reduces the average pump flow from 9.81 gpm down to 9.10 gpm. It also makes the extending no-load pressure very close to the retracting pressure. I calculate this knowing a tank pressure of 100 psi will cause a resistive load requiring 125 psi in regeneration and 180 psi in retraction. This makes it practical to think of this as a two pressure system: one for no-load and one for full load. If we try to store all the fluid in a single accumulator, more than half of the volume will be at a pressure that is higher than what is needed. This extra pressure will have to be reduced as pressure drop across a flow control and will waste energy.

So, the second thing I will do is make it a two accumulator system: one for low pressure and one for high pressure. Now, if I choose to use a single pump to supply both pressures, I will waste energy because the pump will spend about half the time at low pressure, which will not keep the motor running near its capacity. (See the article on Power Factor.)

This brings us to the third feature. I will use a double pump, one side with a flow of 4.06 gpm feeding the low-pressure accumulator at 180 psi, and the other side at 5.04 gpm feeding the high-pressure accumulator at 2816 psi.

The kW requirements for this system will be [(4.06 x 180 / 1714) x 0.7457] + [(5.04 x 2816 / 1714) x 0.7457] for a total of 6.49 kW. When we divide this by the given efficiency of 85%, we get 7.64 kW. (Fig. 2) This is how it works: Start the 7.5 kW motor, and the pumps will charge their respective accumulators to the setting of the unloading valves. Once the pressures are reached, the directional valve is shifted to extend the cylinder at low pressure. The pilot-operated check valves in the circuit cause the cylinder to extend in a regenerative mode. After 24 inches of travel, the directional valve is de-energized and the selector valve is shifted directing high pressure fluid to the cylinder. Fluid is returned through the directional valve. When the cylinder reaches the end of the stroke, the selector valve is de-energized and the directional valve is shifted to direct low-pressure fluid to the rod end of the cylinder causing it to retract. Once retracted, the directional valve is de-energized, and the pumps proceed to replenish the accumulators.

The winner is…well, the winner is all of us who have begun to think more about the way we use energy in our fluid power systems.

May/June 2010 | 13

pumps and motors. A gear pump or motor in good condition is 85% efficient.

So a gear pump driving a gear motor has a best-case efficiency of 0.85 x 0.85 = 0.72. That’s 72% - not considering losses through valves and conductors.

But say a gear-type flow divider was included to achieve multiple wheel drive.

The theoretical efficiency would now be 0.85 x 0.85 x 0.85 = 0.61. That’s 61%, not including losses through valves and conductors. Compare this with a chain drive in good condition, which is 97% to 98% efficient. This explains why you don’t see too many hydraulic bicycles around!

In this application where the available input power is limited by space and weight, the question I had to ask my client was: Can you afford to lose 40% to 50% of available input power to heat? In his case, the answer was no. But in a similar industrial application, we have the luxury of installing a bigger electric motor, without being too concerned about the energy losses--for the time being at least.

Another client is examining his options for a rotary drive in a remote location with no access to the electricity grid. He can generate his own electricity but likes the idea of using an air motor. He wants to know comparative costs. It’s not a big drive--only 20 horsepower.

The

Looming Efficiency

Imperative

By Brendan Casey

In

the current economic climate, the debate concerning peak oil (the end of cheap mineral oil) and global warming (the end of the planet as we know it) have been somewhat sidelined. But these two major issues have not gone away. And they will almost certainly influence the source and cost of our energy needs in the not-too-distant future.

The fact you’re reading this tells me you are involved in industry – directly or indirectly. And there’s no escaping the fact that industry is a huge consumer of energy. If peak oil and global warming are real issues--and there’s a growing body of evidence to suggest they are--then I predict energy management will become a major issue for industry over the next decade and beyond. And a large part of this burden will fall on machine designers.

Efficient By Design

Reliable machines will not be enough. Highly efficient, reliable machines will be required. This begs the question: how efficient are the fluid power machines you design, build, maintain, or repair? Maybe this is an issue you don’t think too much about.

But as a fluid power consultant advising clients in a diverse range of industries, it’s an issue I deal with a lot. Let me illustrate with a couple of examples: One client, the designer of a three-wheeled vehicle, approached me to design a hydraulic drive. He wanted to power at least two-wheels, ideally three.

To keep cost to a minimum, the machine designer asked me to consider gear 14 | May/June 2010

About the Author

Brendan Casey has more than 20 years experience in the maintenance, repair and overhaul of mobile and industrial hydraulic equipment. For more information on reducing the operating cost and increasing the uptime of your hydraulic equipment, visit his Web site: www.HydraulicSupermarket.com.

An air motor has an efficiency of around 15%. So I explained to my client that to drive his 20 horsepower air motor, he’ll need a 140 horsepower air compressor! That pretty much settles it in his application. He’s not going with the pneumatic option. In an industrial situation though, where a large air compressor is already available, these energy losses may be tolerated--for now.

Contrast these two examples with this one: another client for whom I am advising on the design of a 6,000-ton press. Regardless of efficiency, hydraulic power transmission is really his only option. But this is also a relatively efficient use of hydraulics. One of the reasons for this is, in high force applications, the efficiency of a hydraulic cylinder approaches 100%.

And because it’s a high-pressure application, piston pumps will be essential.

The overall efficiency of an axial piston pump in good condition is 92%. So the theoretical efficiency of the press hydraulic circuit is 0.92 x 1 = 0.92 or 92% - not including losses through valves and conductors.

A significant, “built-in” inefficiency in this application, however, is the compressibility of the hydraulic fluid – particularly given the necessarily high working pressure and large volume of the cylinder. But clearly, this is not an application for gear or chain drives.

Consider Efficiency

This is not to say hydraulics, and even pneumatics, aren’t appropriate solutions for rotary drives. Energy efficiency is just one of many issues that must be considered when selecting a power transmission option. But like the many factors that influence machine reliability, if efficiency is overlooked at the design stage and not considered during the equipment selection process, this can increase the lifetime ownership cost of the asset. And even more so in the years come. www.ifps.org | www.fluidpowerjournal.com

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The site offers a number of useful tools for customers and for those who wants to learn more about Yuken. We feature a “Members” section for checking inventory and reviewing service manuals, as well as pricing, on either a downloadable price sheet or an interactive resource. Distributors from across the country and our repair and warranty center information are there. Learn about Yuken’s certifications, check out the product literature, and get a peak at new products, all at our helpful website!

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May/June 2010 | 17

IFPS Certification Success Story:

Alexandria Technical College

IFPS Certification Sets a Standard for Education

A

lexandria Technical College (Alexandria, Minn.) and the International Fluid Power Society (IFPS) share a long history of cooperation and partnership when it comes to certification. In fact, the College is nearly as old as the Society, having been around for 45 years.

18 | May/June 2010

www.ifps.org | www.fluidpowerjournal.com

Alexandria Technical College Certified Individuals (as of March 2010) Robert Auel, AI, CFPAJPP, S, HS, PS, IHT, MHT Tyler Boyer, HS, PT Kevin Dickey, HS, PT

Nathan Eisel, IHM Gary Ellingson, IHT Charles Gervais, PT Michael Hall, IHM Randy Hansen, IHT

The Center for Applied Mechatronics at the College began as a program to train hydraulic test technicians for the industry. As many of the program graduates emerged into fluid power distributorships, however, the Center has evolved with them. It now incorporates the highest level of advance controls and automation technology in its fluid power curriculum.

The Center focuses extensively on the electronics, automation, and communication of fluid power and places as many graduates in the broader field of mechatronics outside of fluid power as it does within the industry.

Founded in 1965, the fluid power program adopted the curricula as outlined by the Fluid Power Educational Committee and began the process of recruiting and training skilled workers for this industry.

Todd Zarbok, AI, AJPP, S, PS, HS, is an instructor at the Center for Applied Mechatronics and provided a history of the College’s partnership with IFPS and how certification has become an essential part of its mission. www.ifps.org | www.fluidpowerjournal.com

Isaak JansenHinnenkamp, IHM Anthony Klisch, IHT Michael Kuelbs, PT Anthony Mohs, HS

Nathan Moyer, PS Eric Reiner, HS Kenneth Ryan, S, HS, PS Nicholas Skoog, PT

“IFPS membership validates the existence of technical education, and membership and certification provide a benchmark to measure the capability of our instructors and students,” he said.

“IFPS is one of the lenses through which we view the industry when advising our fluid power students on career opportunities and industry direction.”

According to Zarbok, the Center maintains an emphasis on the approach to mechantronic systems and is very focused on the integrated control and management of these systems. The Center is deeply involved with the PLCopen Task Force, developing motion control function blocks for the control of fluid power systems in conformance with the IEC 61131-3 programming standard.

He added that nearly all of the certification outcomes are embedded into the Center’s fluid power program. The Center also offers a one-credit study guide course each year to prepare students for the certification exam.

“As governments and other third-party stakeholders in education funding look for benchmarks

Simon Tusler, IHM Wade Wilke, MHT Todd Zarbok, AI, AJPP, S, PS, HS, Nathan Zeroth, HS, PT

for education spending outcomes, industry-endorsed certification will remain a critical efficacy metric,” Zarbok said. “We are fortunate to have such a readily demonstrable and recognizable ‘Brand of Quality’ for our graduates.”

Zarbok said that the benefits of certification are evident within the College, as several certified graduates have enjoyed financial benefits as well as bonus packages from employers because they graduated with certification.

“We will continue to gauge the effectiveness of our fluid power instruction against the IFPS certification ‘standard,’” he said.

For more information on Alexandria Technical College, visit www.alextech.edu.

Todd Zarbok can be reached at toddz@alextech.edu.

May/June 2010 | 19

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A Look At New & Innovative Products

Dual Input Differential Manometer OMEGA Engineering

The new series of manometers feature dual display and dual pressure inputs. Pressure is displayed in one of four user selectable units (psi, mbar, inH2O, and mmH2O). A protective rubber boot is included with the HHP886, and models are available with a USB connection or wireless interface for real time data logging to a computer. Data logging software is included that allows the user to display the data in a graphical format or export the data to Excel or text files for further manipulation. This CE complaint product is ideal for automotive, HVAC, and R&D/lab use. www.omega.com

Ê

ProductReview

Oil/Gas Flow Meter McCrometer

For oil/gas process engineers, the V-Cone® flow meter provides a low-installed and low life cycle cost solution to measuring liquids, gas, or steam.

The process of selecting and sizing is as simple as reviewing a configuration sheet and utilizing the company's sizing software. The entire selection process takes only minutes for most standard oil/gas applications. The unit operates over a wide range of 10:1 with low head loss and supports line sizes from 0.5 to greater than 120 inches. Accuracy is ±0.5% with a repeatability of ±0.1%. www.mccrometer.com

Ê

Pump Tubing Watson Marlow

The GORE high resilience tubing Style 400 is expanded PTFE multi-layer tubing featuring high-performance Viton® filler that is able to maintain a stable flow rate for thousands of hours while pumping aggressive chemicals. The construction makes it suitable for a range of chemicals such as concentrated acids like Nitric and Sulfuric as well as aromatic hydrocarbons like Toluene and Xylene. At continuous pressures of 60 psi, consistent flow rates are achieved throughout the lifetime of the tubing. Internal diameters range from 1.6 up to 12.7 mm, with wall thickness from 1.6 up to 4.8 mm. www.watson-marlow.com

Œ

Differential Pressure Switch Mid-West Instrument

Model 121 indicating differential pressure switch has rugged, field-proven piston/housing and industrial type terminal strip for either one or two switches. Wiring is easy with ½² NPT conduit interface and a removable cover. A variety of switching configurations is available with one or two hermetically sealed switches in SPST, SPDT configuration with 240-volt, 3-watt or 60-watt ratings. Safe working pressure is 6000 psid (0-400 bar). Models are available in differential pressure ranges from 0-5 psid (0-.3 bar) to 0-110 psid (0-7 bar) with ±2% accuracy. The weather resistant gauge front is of reinforced engineered plastic for corrosion resistance. www.midwestinstrument.com

‰

Continued on page 39

Software Showcase Whether you need to manage hose assemblies, keep track of the amount of hose on reels, or send stock items out of the warehouse for rework or assembly, Activant can help. A leading technology provider for the distribution industry, Activant develops solutions and services that help distributors improve customer service and maximize the return on their technology investment. Learn more at distribution.activant.com.

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May/June 2010 | 21

Fluid Power Product Spotlight

By Futek Advanced Sensor Technology, Inc.

The Demand for High Speed Efficient Solutions:

W

ith technology advancing at full speed, it’s only natural for time to be a critical factor in all aspects of daily life: the drive-through windows for fast food, fast search engines in order to obtain information in the quickest way possible, and fastforward buttons on the DVR to speed through commercials during your favorite TV shows. Even social media is playing a part in this fast-paced lifestyle in order to deliver critical news in the quickest way possible. It’s only understandable for engineers to want to receive their data in the fastest way possible, as well.

With the demand of high-speed data retrieval came new technological advancements such as universal serial bus technology (USB). USB technology came about in the early 1990s and since then has come a long way. A universal serial bus is the technology used to connect hardware to a PC in order to deliver fast and efficient information and offer significant advantages in speed over any other type of connection.

For engineers, this new technical knowledge would play an important role in saving time and capturing data in everyday applications. Engineers testing measurements such as force and load involving data logging and sampling would especially benefit from this new invention. In every measurement application involving a sensor, a system is required in order for engineers to be able to collect and analyze data. This system usually includes an amplifier (signal conditioner), analog filter, power supply, and multi-meter. In comparison to this “traditional” sensor system platform, the advantage of a USB Solution is clear.

The Motivation Behind USB

T e c h n o l o g y

As the engineering field became challenged with more innovative and complex sensor applications, this created a need for a low-cost way to capture data more sufficiently and effectively. Applications in industries across the board are becoming more and more involved, and it was only a matter of time before a quick and more efficient solution was needed to obtain output data.

USB drives were becoming very popular and utilized everywhere in the electronic market. This allowed the sensor industry to follow the trend by creating a USB sensor technology for the load cell and sensor market. The USB solution was virtually a “no brainer” due to its portability, as well as its universal capabilities with computers, handheld displays, and PDA devices. One of the main reasons why mechanical engineers decided to go digital was because of the speed a USB output could obtain data compared to the traditional analog output. The USB technology is capable of transferring larger amounts of data in a much shorter amount of time. With a traditional setup, many components are involved in order to provide the final results, increasing the amount of time it would take to receive your data. Not only does this system require several components, but it also involves a complex setup, which may be costly and require the technical support of an engineer, prolonging the process.

Traditional Setup In order to build a traditional sensor system platform, there are several instruments to consider. An ideal platform will include an amplifier/signal conditioner with an active analog filter, which will require an external power supply. In addition, a multi-meter (display) and data storage is necessary. The traditional sensor systems also have some shortcomings, including the power consumption, unwanted noise, and voltage drop-out that would occur if cable range between the amplifier and display instrument was too long. Even if we disregard the economic factor behind such a platform, the task of integrating these instruments all together is no simple feat.

Exploring New Horizons The FUTEK USB kit includes a USB module as well as basic software, making setup complete and user friendly. The software allows a user to easily track and graph data and also features data logging, math functions, and several other functions to help record sensor activity.

With the USB solution, the sensor is directly connected to the USB kit that plugs into a computer, providing quick and easy results. USB is able to run up to 12 MBps and has high-speed capabilities of 480 MBps. This setup has one module and one cable, making the system less confusing. With fewer components, less technical support is required making the system more cost efficient.

The USB solution also provides more stability with the reduction of noise and power supply. Another benefit of this module is its ability to digitally store data.

Data logging is made simpler with USB because the user is given unlimited amounts or opportunities to manipulate and refer back to their data results.

Utilizing the USB solution immediately removes the need for an amplifier (signal conditioner), analog filter, power supply, and multi-meter. The advantages, besides the cost, are the high-resolution digital output, an integrated digital filter to reduce 50 Hz/60 Hz, as well as high-frequency noises and the ability to increase the sampling rate for high-speed applications. Other benefits include the capability to store calibration values inside the on-board non-volatile memory (in order to apply the real-time calculation to account non-linearity), and also other configurations that are usually stored in a TEDS chip (which is no longer needed).

The presence of a powerful micro-controller beside a high accuracy deltasigma analog to digital converter (ADC) not only eliminates analog circuitry (that reduces the sensitivity to environment conditions such as temperature, humidity, and noise) but also introduces an intelligent digital system, which is able to activate internal circuits such as shunt cal, short circuit protection, built-in auto-calibration, integrated temperature sensor, sampling rate changer, etc., following the user prompt.

Furthermore, using the high-speed, bi-directional USB link gives the user power to communicate with the sensor by PC-based software and monitor/ control the functionality of features such as tare, peak, valley, and selectable averaging without any need to change the hardware settings manually. FUTEK also offers a USB solution for a multiple sensor platform. With the USB multiple platform, there is no longer a need for multiple instruments to make the platform work. Engineers are able to connect up to 127 sensors using the USB sensor solution on one port by utilizing multiple hubs. Furthermore, instruments (booster) can be provided so the system can be extended to operate on a 150 feet (45 meters) distance with no impact on the electronic noise. Such options are not easily available or user friendly for sensors that are operating on analog platforms. The greatest advantage with such a system is that it provides flexibility in system control. If there is a failure point in the system, it is much easier to determine where and which precise sensor it is that has failed.

To learn more about USB Technology or FUTEK’s USB kits visit http://www.futek.com/USBSensors.aspx.

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D03..D05..D08..Modulars Power Valve Power Valve U.S.A. represents, as factory warehouse and sales office, a Taiwan manufacuturer of D03 and D05 valves, and their associated line of modular stack valves. With the warehouse in Houston, and inventory waiting, all products are very competitively priced, and Taiwan machine tool quality is built into every valve. In fact, the parent company, Tai Huei Oil Industry Co., Ltd. has been selling industrial directional solenoid valves for over 25 years to their machine tool industry customers. All coil ratings in AC and DC voltages are available, and all possible spool configurations have been produced at one time or another by the parent company. Pressure to 5000psi and flows to 16gpm (D03) and 27gpm (D05) are standard. With our commitment to inventory on the shelf, and our very competitive pricing, we invite your inquiry.

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May/June 2010 | 27

This is

Vacuum

By Daniel Pascoe

U.n.i.t.s o.f M.e.a.s.u.r.e.m.e.n.t

A

confusing aspect of vacuum engineering are the units of measurement used in the industry. Depending on the origin of product catalogues or indeed the intended target industry, the units of measurements will vary widely.

Vacuum Level

Understand this. There is no such thing as vacuum measurement. It is atmospheric pressure you are measuring. The two differences in the vacuum industry are either the measurement of differential or absolute pressure. In North America and in particular the United States, general industry uses inches of mercury ("Hg) and is by far the most common terminology in use. This is a differential unit of measurement. This means that it is a measurement of pressure (but always referred to as vacuum) with the datum point taken from the existing atmospheric pressure. The higher the number, the higher the vacuum. For example, when a vacuum pump or venturi starts to create a vacuum in a known, fixed volume, the "Hg scale starts to increase, rising from zero to the final pressure (vacuum) level, which has been determined by the performance of the pump or the application itself. The standard maximum number for "Hg is 29.92, as this is a standard “atmospheric pressure.”

Atmospheric pressure is created by a column of air pressing down onto the surface of the earth. In real world terms, imagine a square inch of surface area.

This will have a force of 14.7 psi pressing down on it. This pressure is what vacuum engineers are reducing in a known volume. Of course, atmospheric pressure varies based on weather activity, or what is more comprehensible, the altitude of the machinery compared to sea level. At sea level, which is a constant height across the globe, the following standard atmospheric pressures are applicable: 29.92"Hg, 14.696 psi, 760 mmHg (Torr), 1013 mbar, and 100 kPa. Fig. 1 demonstrates these values and shows if they are normally used in a differential (starts from zero) or an absolute (ends in zero) scale in our industry.

The industrial application normally dictates the unit of vacuum level. In a simple vacuum cup pick-and-place system, "Hg is the most common, certainly in North America, whereas in Europe, kPa is the preferred choice. This is because the amount of vacuum required is generally low, peaking at <27"Hg or -90 kPa. However, if the user must know the final atmospheric pressure, an absolute scale should be used. Industries such as vacuum deposition (coating) or semiconductor manufacturing where the atmosphere must be clean (as few gas molecules as possible), a much higher vacuum is required. Therefore, an absolute measurement should be used such as mbar (millibar). It is not uncom28 | May/June 2010

mon for this industry to use a sliding vane pump to create an initial vacuum of 0.02 mbar(a) and then a turbomolecular pump to generate in excess of 0.00001 mbar(a). Notice the (a) after the number.

This dictates it is a measurement based on absolute zero atmospheric pressure, which is always a constant unlike the atmospheric pressure, which a differential measurement uses as its datum point.

Mbar(a) is common in European countries whereas in North America, Torr (mmHg) is the preferred choice. Both are absolute scales and offer the same accuracy of absolute pressure measurement.

Vacuum Flow

Flow in a vacuum system is always confusing to people as they can't visualize the air in a vacuum system. Think of it like this: air is made up of gas molecules, microscopic of course but a physical mass nonetheless. It is these gas molecules that you are removing. Pressure is created by the density of gas molecules in a known volume. If you double the amount of gas molecules in a volume (using a compressor), then you have doubled the pressure. Consequently, if you extract half of the gas molecules in a known volume, then you will half the pressure, or in the case of vacuum, if the initial pressure was one atmosphere, you have now created a vacuum of -50kPa or 15 "Hg or 380 Torr, etc.

The units of measurement used to measure vacuum flow vary as much as vacuum level measurement. In North America, the most common by far is CFM or cubic feet per minute. This means that the pump or venturi will extract so many cfm in a known volume. There is also much confusion as to the difference between SCFM and ACFM. SCFM is a volume of air assumed at a standard condition based on atmospheric pressure, temperature, and humidity. This standard varies even within the same countries, let alone continents, so always refer to the manufacturers’ data sheets to see what they are basing their SCFM units on. However, 1 scfm is a standard “lump” of air full of the normal amount of gas molecules found in a cubic foot of air at sea level. As the vacuum level increases, the SCFM decreases with it at a near linear rate (Fig. 2) as there are less and less gas molecules in the application. This is why when a vacuum pump first starts to evacuate a volume, there is a lot of flow out of the pump exhaust, but as the vacuum pump decreases the pressure (increases the vacuum), the flow from the exhaust decreases. Therefore at a vacuum of 29 "Hg, there is hardly any flow (SCFM) at all.

However ACFM is the flow at the vacuum level. Therefore, theoretically, 100 acfm at 15 "Hg is the same as 50 scfm because at 15 "Hg, there is half the amount of gas molecules. Therefore, when you specify a vacuum pump on a customer request, make sure he is quoting you either ACFM or SCFM. The other common units of measurement are cubic meters, liters, or milliliters (metre, litre, and milliletre in European spelling). Therefore on European pump data sheets, you will see m3/hr, m3/min or l/min or l/sec--quite the variation and based upon the manufacturer’s preference. The good thing about the European www.ifps.org | www.fluidpowerjournal.com

system is that it’s all divisible by 60 (minutes to seconds or hours to minutes) or 1000 (meter cubed to liters). So jumping between one manufacturer and the next is relatively easy. Fig. 2 demonstrates the difference in m3/hr, actual m3/hr (ACFM), and standard m3/hr (SCFM). Also, as you can see from the graph in Fig. 2, manufacturers give a time curve as well for a given volume to assist the user in sizing the equipment for a given application.

Vacuum pumps or venturi are used for one thing and one thing only. To “pump” down a volume to a particular vacuum level in a certain amount of time, and the reason for one pump being larger than the other is simply to do it faster. This volume might be the internal volume of a vacuum cup and associated hoses or a space simulation vessel some 100 feet in diameter. Either way, an application engineer needs to know three things: the vacuum level required, the volume to be evacuated, and the time in which it is to take. The fourth and generally the most important thing they need to know is what the application is. That will determine what type of pump is required and all the accessories needed to ensure a safe, reliable, and correct application of vacuum equipment.

This article is intended as a general guide and as with any industrial application involving machinery choice, independent professional advice should be sought to ensure correct selection and installation.

Fig. 2

Fig. 1

Daniel Pascoe is general manager of Vacuforce Inc., which specializes in the application of vacuum systems and components for industry in North America. Daniel can be reached via the Vacuforce Web site at www.vacuforce.com.

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May/June 2010 | 29

Design & CFD Aided

of Valves

Pumps

In

By Sam Lowry, PhD, President, and Zhemin Wu, PhD, Research Engineer, Simerics, Inc.

hydraulic systems, pumps and valves can work together smoothly or in unwanted conflict. The efficiency, smoothness, and durability of their interaction ultimately derive from the skill and knowledge of the designer. Established guidelines, one-dimensional models, and experience can go a long way toward optimizing pump-valve interaction. However, even the most experienced designer can be overwhelmed when confronted with complex systems where three-dimensional effects, unintended resonances, and cavitation may severely degrade the valve performance.

Fortunately, recent advances in three-dimentotype to a high fidelity CFD model in less than

30 | May/June 2010

sional Computation Fluid Dynamics (CFD) now make it possible to numerically simulate the interaction of hydraulic valves and pumps on a computer, with the same accuracy as a hardware test. Typically, such virtual tests can be accomplished at less cost and in less time. The resulting model not only predicts the combined pump and valve performance but also provides unique insight into the dynamics of the system through the use of images and animations.

Recent advances in simulation have made testing a pump-valve system on a desktop computer not only possible but practical, as well.

These advances include improvements in both computer hardware and software. Faster CPU and multi-core machines, coupled with more efficient numerical algorithms, have reduced the duration of transient simulations of complex systems to a matter of hours. With the aid of a Graphical User Interface (GUI) and templates, the designer can transition straight from a CAD pro-

an hour and get results before the end of the day.

This ease of set-up and speed of calculation makes numerical simulation an effective complement to hardware testing in terms of productivity.

And advances in physical models and numerics have enabled the development of comprehensive simulation tools that robustly incorporate important physical phenomena, such as pressure ripple and cavitation, making the data from these models as realistic as actual tests.

The first of these, pressure ripples, can contribute to noise, damage, and system instabilities. Fig. 3 shows a comparison between a numerical simulation and measured pressures in three locations in the outlet pipe of a positive displacement pump. The red lines are experimental data and the blue lines are the corresponding pressure profiles predicted by the simulation tool. The simulation matches both the amplitude and frequency very well, making it possible to analyze the effects of hardware www.ifps.org | www.fluidpowerjournal.com

Fig.1: PumpLinx® simulation of valve dynamics during start-up of an external gear pump. The color map on the left corresponds to the velocity magnitude.

(Red is the maximum and blue is the minimum). The plot on the top right is the pressure history near the valve inlet. The plot on the bottom right is the valve displacement versus time.

Fig.2

Fig.1

Fig.3

Fig.4 Fig. 2: Cavitation in a poppet valve (Magenta indicates 100% gas) Fig. 3: Prediction of pressure ripples in the outlet of a positive displacement (PD) pump with comparison to data Fig. 4: Valve dynamic equation Fig. 5: Predicted pressure and valve opening vs. time. Resonant valve 1 vs. non-resonant valve 2 (mass increased 3.5 times) modifications on the performance, before creating a physical prototype.

In addition to pressure ripple, cavitation is often a serious concern in pump-valve performance.

Cavitation can influence the flow rate, increase noise, and cause damage to surfaces. Fig. 2 shows the predicted cavitation in a 3-D poppet valve. The magenta color corresponds to regions of 100% vapor. In order to model this phenomena, the simulation tool must be able to model flow and cavitation in very small gaps, e.g. on the order of microns, and to account for the formation, transport, and compressibility of both the vapor and any air entrained in the liquid. Simulations such as these can be used to generate flow vs. pressure curves (Q-DP) and to determine potential areas of cavitation damage. Dynamics simulations, in which the valve position is either explicitly controlled or free to move in response to pressure forces, can be used to determine how it will respond in a dynamic system.

The forces on a valve include both fluid forces and mechanical loads. These forces are integrated during the course of a simulation and used to determine the dynamics of the valve based on the inertial and combined forces, as shown for a spool valve in Fig. 4. When incorporated into a system, the motion of the valve interacts with the system pressure, which in turn can influence the valve motion. Fig. 5 shows the predicted up-

The pressure pulsation, measured near the inlet of the valve, causes an oscillation of the valve about its average open position. Inspection of the properties assigned for valve 1 in this model would reveal that the spring constant “k” and the mass “m” are set such that the resonant frequency of the valve

ƒresonance = 21π

Fig.5 stream pressure and valve displacement during the steady operation of the external gear pump shown in Fig. 1. The slave and drive gears in the pump each have twelve teeth, rotating at 3000 rpm. The corresponding frequency generated by a single gear is 600 hz but twice that for the system, as the two gears mesh. This 1200-hz pulsation is evident in the pressure plot in Fig. 5.

k

m´

equals the 600 hz of the tooth passage for a single gear. The resultant peak-to-peak amplitude of the valve oscillations is predicted to be approximately 40 microns at 600 hz, with a stutter step in between. Increasing the mass of the valve by a noninteger (specifically increasing it by a factor of 3.5) changes the natural frequency of the valve. This increase in mass and de-tuning of valve 2 reduces the amplitude of the valve oscillations by a factor of 5, as shown in Fig. 5.

In summary, new simulation technology enables an engineer to test CAD prototypes of pump-valve systems rapidly and accurately on a desktop computer.

The model created is fully three-dimensional and provides accurate engineering data for pressures, cavitation, aeration, torques, valve dynamics, flow rates, hydrodynamics loads, and other critical parameters.

How the above data might help optimize a system still depends on the skill and knowledge of the designer, but recent advances in CFD now provide a new tool that he or she can use in applying that skill.

For more information, contact Simerics at www.simerics.com.

AssociationNews

NFPA | National Fluid Power Association

NFPA’s 2010 Industry and Economic Outlook Conference August 17 – 18, 2010 Westin Chicago North Shore Wheeling, IL • Mobile and industrial market breakout sessions • Advances across the supply chain • Power of Association Reception and Dinner is a conference networking highlight, providing the best possible opportunity to interact with the entire conference delegation.

• Supplier tabletop exhibits, which feature networking opportunities with industry suppliers demonstrating product.

Don’t miss out on one of the “Can’t Miss Events of 2010!” To learn more about the conference visit www.nfpa.com or call 414-778-3344.

Calendar of Events

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oin NFPA at the intersection of marketing and strategy for the highly acclaimed Industry and Economic Outlook Conference, August 1718, 2010, at the Westin Chicago North Shore Hotel. This day-and-half event offers hard data and expert analysis on tomorrow’s economic environment with an additional focus into the technology advancements likely to impact the fluid power supply chain in the years ahead.

A conference like no other, this year’s Industry and Economic Outlook Conference will offer critical insight into economics, market forecasts, technology, plus unparalleled networking opportunities.

Conference highlights include • Global economic trends Alan Beaulieu, Institute for Trend Research (ITR) • Fluid power customer market overview Eli Lustgarten, ESL Consultants, Inc. • Fluid power market forecast Jim Meil, Eaton Corporation • Regulatory Landscape Aric Newhouse, National Association of Manufacturers (NAM) 32 | May/June 2010

NFPA’s Economic Update Webcast May 20, 2010 10:00 am Central By: Jim Meal, Eaton Corporation Supplier Golf Invitational August 16, 2010 Chevy Chase Country Club, Wheeling, IL NFPA 2010 Industry and Economic Outlook Conference August 17 – 18, 2010 Westin Chicago North Shore, Wheeling, IL NFPA’s Economic Update Webcast October 28, 2010 10:00 am Central By: Alan Beaulieu, Institute for Trend Research

2011 NFPA Annual Conference February 16 – 19, 2011 Hyatt Regency Coconut Point, Bonita Springs, FL IFPE 2011 March 22 – 26, 2011 Las Vegas Convention Center, Las Vegas, NV co-located with CONEXPO-Con/AGG. Please check www.ifpe.com for more details.

August 16 – 17, 2011 NFPA 2010 Industry and Economic Outlook Conference Renaissance Schaumburg Hotel, Schaumburg, IL

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FPDA | Motion & Control Network

FPDA/ISD Industry Summit Scheduled for October 5-8, 2010 at PGA National Resort & SPA, West Palm Beach, Florida The 2010 FPDA/ISD Joint Summit will offer not only new potential marketing partners but also new programming features, as well. A products showcase, in-depth educational offerings, the popular golf tournament, and more await FPDA and ISD delegates at the PGA National Resort & Spa in West Palm Beach, Fla. In addition to a program stuffed with take-home value, the PGA Resort is offering a competitive rate of $140 a night for accommodations.

FPDA members will meet with the members of the International Sealing Distribution Association, the association for fluid sealing professionals. ISD members are distributors and manufacturers of fluid sealing products and/or fluid sealing services to industry, institutions, end users, and/or original equipment manufacturers.

FPDA Announces Upcoming Webinars HOW TO BE SUCCESSFUL WITH E-MAIL MARKETING Tuesday, May 11, 2010, 1:00pm EST Is your e-mail newsletter a success? The big challenge in producing a successful e-mail newsletter is generating content that will motivate prospects and customers to open, read, and respond. E-newsletters that simply provide a recap of your latest products and news may be of great interest to you, but they are of little interest to your readers.

This webinar will show how to make an e-newsletter a “must read” and a valuable nurturing tool for your business. You will learn proven tips to • Define an effective e-mail marketing strategy • Build your list and gain permission • Create content your customers will love • Measure the success of your e-mail marketing efforts • And more!

These webinars are offered at $149 for members. For details, contact FPDA at 410-940-6347.

ESA Welcomes New Members Ferm Hydraulics, Inc. Yuba City, CA International Fluid Power Society (IFPS) Cherry Hill, NJ www.ifps.org SWECO Products, Inc. Sutter, CA www.swecoproducts.com

...12GPM...16GPM...21GPM ...13GPM...21GPM...37GPM

Wiley Equipment Co. Inc. El Segundo, CA For information about joining the Equipment Service Association, please visit www.2esa.org or call 866-ESA-3155. www.ifps.org | www.fluidpowerjournal.com

...machine tool quality from Taiwan Request more information at www.fluidpowerjournal.com

May/June 2010 | 33

AssociationNews Certification Levels Available: C F PA I Certified Fluid Power Accredited Instructor C F PA J P P Certified Fluid Power Authorized Job Performance Proctor C F PA J P P C C Certified Fluid Power Authorized Job Performance Proctor Connector & Conductor

IFPS | International Fluid Power Society

IFPS is now on Facebook and LinkedIn Come Join Us!

CFPMM Certified Fluid Power Master Mechanic

IFPS Newly Certified

CFPIHM Certified Fluid Power Industrial Hydraulic Mechanic CFPMHM Certified Fluid Power Mobile Hydraulic Mechanic CFPPM Certified Fluid Power Pneumatic Mechanic CFPMT Certifed Fluid Power Master Technician CFPIHT Certified Fluid Power Industrial Hydraulic Technician CFPMHT Certified Fluid Power Mobile Hydraulic Technician CFPPT Certified Fluid Power Pneumatic Technician CFPS Certified Fluid Power Specialist (Must Obtain CFPHS, CFPPS) CFPHS Certified Fluid Power Hydraulic Specialist CFPPS Certified Fluid Power Pneumatic Specialist CFPE Certified Fluid Power Engineer CFPCC Certified Fluid Power Connector & Conductor CFPMIH Certified Fluid Power Master of Industrial Hydraulics CFPMMH Certified Fluid Power Master of Mobile Hydraulics CFPMIP Certified Fluid Power Master of Industrial Pneumatics

34 | May/June 2010

Thomas Anderson, PS

Anthony Hallberg, PS

Benjamin Parker, HS

Wayne Bennett, CC The Boeing Company

Wayne Harkleroad, MHM Bonneville Power Administration

Craig Peachey, IHT Alcoa Mill Products, Inc.

Bryan Bland, CC The Boeing Company

David Heath, MHM

Ross Peterson, PS

Ben Henning, S, PS

Leif Sammons, MHM Titan Truck Equipment

Jay Brewer, IHM Kellogg

Robert Hestness, PS

Jon Burkhart, IHT Alcoa Mill Products, Inc.

Teresa Holder, CC The Boeing Company

Marcus Consoer, S, PS Hennepin Technical College

Eric Itow, PS

Robin Sand, PS Don Schaub, HS McNelius Truck & Mfg.

Lee Jefferson, MHM

Lonnie Schoonover, MHM Okanogan County PUD

Gregory Jones, IHM Kellogg

Ryan Seger, HS Parker Hannifin Corporation

Eric Karr, PT Alcoa Mill Products, Inc.

Michael Shimek, IHM Kellogg

Adam Kiourkas, MHM Titan Truck Equipment

Jon Siegle, PS Hennepin Technical College

Liza Esterly, PS

David Lang, PS Hennepin Technical College

Casey Smith, CC The Boeing Company

Randall Flick, IHT Alcoa Mill Products, Inc.

Thomas McGuire, HS Eaton Corporation

Mike Stevens, MHM Kootenai Electric

Benjamin Flygare, PS

Brandt McLinden, MHM Mission Valley Power

Travis Tester, MHM Grant County PUD

Jeffrey Mock, MHM Titan Truck Equipment

James Van Ness, MHM

James Crooks, MHM Titan Truck Equipment Andrew Dammann, PS Randy Dewitt, CC The Boeing Company Stephen Esmieu, MHM Titan Truck Equipment

Russell Fry, IHM Kellogg Doug Gillingham, MHM Titan Truck Equipment Rene Grenier, CC The Boeing Company

Johnny Vetter, MHM Anthony Montabon, HS Eaton Hydraulics

Mickey (Michael) Yarger, IHM Kellogg

Jerzy Nowak, CC The Boeing Company www.ifps.org | www.fluidpowerjournal.com

Job Performance Tests The Job Performance Test is the “hands-on” portion of an IFPS certification test. It is a three (3)-hour test composed of five (5) or six (6) separate stations depending on the level. The IFPS Job Performance Test is required for the Connector & Conductor certification level test, as well as all Mechanic and Technician level certifications. All IFPS certification level tests also require a written test.

IFPS Certification Tests Go Paperless

2010 Job Performance Test Locations 5/01/10

PA College of Technology - Montgomery, PA

5/27/10

Altec Industries - Dixon, CA

8/04/10 C&C

Eaton Corporation - Eden Prairie, MN

8/26/10

Altec Industries - Aurora, CO

9/16/10

Altec Industries - Portland, OR

10/29/10

Altec Industries - Forest Park, GA

All IFPS certification tests are now offered online at most testing sites. Online test results are compiled and returned in a matter of seconds. A competency report is also generated, letting you know your strengths and weaknesses in each domain. Paper and pencil tests are available by special request; however, there is a three-week waiting period for test results.

Colleges and universities across the United States and Canada have testing centers at their facilities. Arrangements are made through the IFPS for you to take your certification tests at these locations. A complete list of testing sites can be viewed on the next page. To register, visit www.ifps.org.

Request more information at www.fluidpowerjournal.com

www.ifps.org | www.fluidpowerjournal.com

May/June 2010 | 35

AssociationNews

IFPS | International Fluid Power Society

IFPS Certification Testing Locations

I

ndividuals wishing to take any IFPS written certification tests are able to select from approximately 265 convenient locations across the United States and Canada. The IFPS is able to offer these locations through its affiliation with The Consortium of College Testing Centers (CCTC) provided by National College Testing Association (NCTA).

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

2. Submit your application with payment to IFPS Headquarters.

3. Upon receipt of your application, you will be emailed instructions. Testing dates for any locations listed below are as follows: May 2010 June 2010 Tuesday, 5/4 Tuesday, 6/1 Thursday, 5/20 Thursday, 6/17

July 2010 August 2010 September 2010 Tuesday, 7/6 Tuesday, 8/3 Tuesday, 9/7 Thursday, 7/15 Thursday, 8/19 Thursday, 9/16

October 2010 November 2010 Tuesday, 10/5 Tuesday, 11/2 Thursday, 10/21 Thursday, 11/18

December 2010 Tuesday, 12/7 Thursday, 12/16

If you have any questions, please call IFPS Headquarters at 800-308-6005 or e-mail Connie Graham at cgraham@ifps.org.

ALASKA University of Alaska Anchorage Anchorage, AK ALABAMA Alabama A&M University Normal, AL Jacksonville State University Jacksonville, AL University of AL in Huntsville Huntsville, AL University of Alabama at Birmingham Birmingham, AL ARKANSAS Northwest Arkansas Community College | Bentonville, AR ARIZONA Arizona State University Tempe, AZ Arizona Western College Yuma, AZ Coconino Community College Flagstaff, AZ Eastern Arizona College Thatcher, AZ

Fullerton Community College Fullerton, CA

University of Delaware Newark, DE

University of Georgia Athens, GA

Richland Community College Decatur, IL

Irvine Valley College Irvine, CA

FLORIDA Brevard Community College Cocoa, FL

University of West Georgia Carrollton, GA

Rock Valley College Rockford, IL

Valdosta State University Valdosta, GA

University of Illinois at Urbana Champaign, IL

HAWAII BYU-Hawaii Laie, HI

Waubonsee Community College Grove, IL

La Sierra University Riverside, CA National Test Center San Diego, CA National University San Diego, CA Santa Rosa Junior College Santa Rosa, CA Skyline College San Bruno, CA The Taft University System Santa Ana, CA UC San Diego Extension San Diego, CA University of California Irvine, CA Yuba Community College Marysville, CA

Daytona State College Daytona Beach, FL Florida Atlantic University Boca Raton, FL Florida Gulf Coast University Ft. Myers, FL Florida Memorial University Miami Gardens, FL Hillsborough Community College Plant City, FL Miami Dade College Miami, FL Open Campus Florida Community College at Jacksonville, FL Palm Beach Community College North Campus | Palm Beach Gardens, FL Santa Fe Community College Gainesville, FL

Glendale Community College Glendale, AZ

COLORADO Community College of Aurora Aurora, CO

Mesa Community College Mesa, AZ

Community College of Denver Denver, CO

University of South Florida Tampa, FL

Northern Arizona University Flagstaff, AZ

Fort Lewis College Durango, CO

Valencia Community College Orlando, FL

Paradise Valley Community College Phoenix, AZ

Front Range Community College Larimer Campus | Ft. Collins, CO

Pima Community College Tucson, AZ

Pikes Peak Community College Colorado Springs, CO

GEORGIA Albany State University Albany, GA

Rio Salado College Tempe, AZ

Pueblo Community College Pueblo, CO

CALIFORNIA Allan Hancock College Santa Maria, CA

University of Colorado at Boulder Boulder, CO

California Polytechnic State University San Luis Obispo, CA California State University, Fresno Fresno, CA

University of Northern Colorado Greeley, CO CONNECTICUT Yale University | New Haven, CT

Chapman University Orange, CA

DELAWARE Delaware State University Dover, DE

Foothill College Los Altos Hills, CA

Delaware Technical and Community College | Georgetown, DE

36 | May/June 2010

University of Florida Gainesville, FL

Clayton State University Morrow, GA Columbus State University Columbus, GA Columbus Technical College Columbus, GA Darton College Albany, GA Georgia Gwinnett College Lawrenceville, GA Georgia Southern University Statesboro, GA Georgia State University Atlanta, GA

IOWA Hawkeye Community College Waterloo, IA University of Iowa Iowa City, IA

INDIANA Indiana Univ. Purdue University Indianapolis, IN Ivy Tech Community College/ Bloomington | Bloomington, IN Ivy Tech Community College/ Columbus | Columbus, IN

Wartburg College Waverly, IA Western Iowa Community College Sioux City, IA IDAHO Boise State University Boise, ID

Ivy Tech Community College/ Evansville | Evansville, IN Ivy Tech Community College/Gary Gary, IN Ivy Tech Community College/ Indianapolis | Indianapolis, IN

Brigham Young University Rexburg, ID

Ivy Tech Community College/Kokomo Kokomo, IN

College of Southern Idaho Twin Falls, ID Eastern Idaho Technical College Idaho Falls, ID Lewis-Clark State College Lewiston, ID

Ivy Tech Community College/ Lafayette | Lafayette, IN Ivy Tech Community College/ Lawrenceburg | Lawrenceburg, IN Ivy Tech Community College/Madison Madison, IN

University of Idaho Moscow, ID

Ivy Tech Community College/Muncie Muncie, IN

ILLINOIS College of DuPage Glen Ellyn, IL

Ivy Tech Community College/ Richmond | Richmond, IN

College of Lake County Grayslake, IL

Ivy Tech Community College/ Sellersburg | Sellersburg, IN

Illinois State University Normal, IL

Ivy Tech Community College/South Bend | South Bend, IN

John A. Logan Community College Carterville, IL

Ivy Tech Community College Terre Haute, IN

Lincoln Land Community College Springfield, IL

Purdue University West Lafayette, IN

Northern Illinois University De Kalb, IL

KANSAS Johnson County Community College Overland Park, KS

Parkland College Champaign, IL

Kansas State University Manhattan, KS

www.ifps.org | www.fluidpowerjournal.com

University of Kansas Lawrence, KS Wichita State University Wichita, KS KENTUCKY University of Louisville Louisville, KY Western Kentucky University Bowling Green, KY LOUISIANA Bossier Parish Community College Bossier City, LA

MINNESOTA Minnesota State University, Mankato Mankato, MN

Raritan Valley Community College Somerville, NJ

HACC Gettysburg Campus Gettysburg, PA

Texas A&M University-Commerce Commerce, TX

University of Minnesota - Twin Cities Minneapolis, MN

NEW MEXICO Eastern New Mexico University Portales, NM

Harrisburg Area Community College Harrisburg, PA

Texas Tech University Lubbock, TX

University of Minnesota Morris, MN

San Juan College Farmington, NM

MISSOURI Avila University Kansas City, MO

NEVADA College of Southern Nevada Charleston Campus Las Vegas, NV

Metropolitan Community College-Penn Valley | Kansas City, MO

College of Southern Nevada Cheyenne Campus North Las Vegas, NV

University of Louisiana at Monroe Monroe, LA

Missouri Western State University St.Joseph, MO

Nicholls State University, Thibodaux, LA

Southeast Missouri State University Cape Girardeau, MO

College of Southern Nevada Green Valley Campus Henderson, NV

University of New Orleans New Orleans, LA

St. Charles Community College Cottleville, MO

College of Southern Nevada Henderson Campus, NV

MARYLAND Anne Arundel Community College Arnold, MD

State Fair Community College Sedalia, MO

NEW YORK Brooklyn College - CUNY Brooklyn, NY

Carroll Community College Westminster, MD Chesapeake College Wye Mills, MD College of Southern Maryland La Plata, MD

Three Rivers Community College Poplar Bluff, MO University of Central Missouri Warrensburg, MO Webster University St. Louis, MO

Frederick Community College Frederick, MD

MISSISSIPPI Holmes Community College Goodman Campus | Goodman, MS

Harford Community College Bel Air, MD

Mississippi State University Mississippi State, MS

Hagerstown Community College Hagerstown, MD

University of Mississippi University, MS

Howard Community College Columbia, MD

MONTANA Montana State University Bozeman, MT

University of Maryland College Park, MD

Rochester Institute of Technology Rochester, NY OHIO Central Ohio Tech College/OSUNewark | Newark, OH

Rhodes State College Lima, OH

Salt Lake Community College Salt Lake City, UT Utah Valley State College Orem, UT Weber State University Ogden, UT VIRGINIA Old Dominion University Norfolk, VA

WISCONSIN Lakeshore Technical College Cleveland, WI

Austin Community College Austin, TX

Marian University of Fond du Lac Fond du Lac, WI

Collin Community College - Spring Creek Campus | Plano, TX

University of Wisconsin Oshkosh Oshkosh, WI

Eastfield College Mesquite, TX

University of Wisconsin-Milwaukee Milwaukee, WI

El Paso Community College El Paso, TX

UW-Green Bay Green Bay, WI

Clackamas Community College Oregon City, OR

Grayson County College Denison, TX

WYOMING University of Wyoming Laramie, WY

Mt. Hood Community College Gresham, OR

Lamar Institute of Technology Beaumont, TX

Portland Community College Rock Creek Portland, OR

Lamar University Beaumont, TX

Portland State University Portland, OR

Midwestern State University Wichita Falls, TX

RCC-SOU Higher Education Center Medford, OR

Sam Houston State University Huntsville, TX

Southwestern Oregon Community College | Coos Bay, OR

Southern Methodist University Dallas, TX

University of Oregon Eugene, OR

Texas A&M International University Laredo, TX

Ferris State University Big Rapids, MI

North Carolina Central University Durham, NC

University of Oklahoma Norman, OK

Henry Ford Community College Dearborn, MI

North Dakota State University Fargo, NC

Kalamazoo Valley Community College Kalamazoo, MI

The University of North Carolina Wilmington, NC

OREGON Central Oregon Community College Bend, OR

Lake Superior State University Sault Ste. Marie, MI

NORTH DAKOTA Bismarck State College Bismarck, ND

www.ifps.org | www.fluidpowerjournal.com

Davis Applied Technology College Kaysville, UT

TEXAS Abilene Christian University Abilene, TX

University of Central Oklahoma Edmond, OK

Mercer County Community College West Windsor, NJ

UTAH Brigham Young University Provo, UT

Western Washington University Bellingham, WA

Mount Olive College Mount Olive, NC

Washtenaw Community College Ann Arbor, MI

Weatherford College Weatherford, TX

Walters State Community College Morristown, TN

Delta College University Center, MI

Southwestern Michigan College Dowagiac, MI

Middle Tennessee State University Murfreesboro, TN

Victoria College Victoria, TX

South Seattle Community College Seattle, WA

Oklahoma State University-Tulsa Tulsa, OK

Gloucester County College Sewell, NJ

Trident Technical College Charleston, SC

University of Texas El Paso El Paso, TX

The University of Memphis Memphis, TN

Guilford Technical Community College Jamestown, NC

Schoolcraft College Livonia, MI

Technical College of the Lowcountry Beaufort, SC

University of Texas at Arlington Arlington, TX

Olympic College Bremerton, WA

MICHIGAN Baker College Online Flint, MI

NEW JERSEY Brookdale Community College Lincroft, NJ

Spartanburg Community College Spartanburg, SC

University of Texas - Brownsville Brownsville, TX

Tennessee State University Nashville, TN

The University of Toledo Toledo, OH

Oklahoma State University Stillwater, OK

Southeast Community College Lincoln, NE

Piedmont Technical College Greenwood, SC

University of Houston Houston, TX

WASHINGTON Central Washington University Ellensburg, WA

Fayetteville State University Fayetteville, NC

Michigan State University East Lansing, MI

Orangeburg Calhoun Technical College Orangeburg, SC

Tyler Jr. College Tyler, TX

Southern Adventist University Collegedale, TN

The Ohio State University Columbus, OH

Boston, MA

Macomb Community College Warren, MI

Midlands Technical College Columbia, SC

TENNESSEE East Tennessee State University Johnson City, TN

OKLAHOMA Northern Oklahoma College Tonkawa, OK

NEBRASKA Bellevue University Bellevue, NE

Horry-Georgetown Technical College Conway, SC

Franklin University Columbus, OH

NORTH CAROLINA East Carolina University Greenville, NC

Lansing Community College Lansing, MI

SOUTH CAROLINA Coastal Carolina University Conway, SC

York Technical College Rock Hill, SC

University of Akron Akron, OH

University of Massachusetts

Harrisburg Area Community CollegeLancaster Campus | Lancaster, PA

Columbus State Community College Columbus, OH

The University of Montana Missoula, MT

MASSACHUSETTS North Shore Community College Danvers, MA

Harrisburg Area Community College York Campus | York, PA

PENNSYLVANIA Bucks County Community College Newtown, PA

CANADA Lethbridge College Lethbridge, AB Canada Saskatchewan Institute of Applied Science and Technology Saskatchewan, Canada Thompson Rivers University Kamloops, BC Canada

Texas A&M University College Station, TX

May/June 2010 | 37

ProfessionalDevelopment

By Heather Lutze

Reinvent

Relationships with Your Customers Online

C

ompanies spend millions each year asking agencies and marketers to brand their companies in order to reach more prospects. But how often do these same companies look carefully at the brand that is already built for them by their loyal, current customers? Like it or not, your “fan base” already has built your brand and holds your company’s reputation in the palms of their hands through an aggregate of blog posts, review sites, videos, and social media platforms stating what they love and hate about your brand. In the event that this is prominently positive, how do you get everyone to collectively support your brand as a community of evangelists for your company? The answer is to start loving your devotees and to give them what they want--a place to network, talk, share advice, and continue to preach about your brand. In end, this is what large corporations pay the big bucks for--reverse marketing by and for your already loyal customers--and it’s something you can do yourself.

Take for example a small company in a predicament. Company founders had built a tremendous brand and had a huge following, however, the brand was fragmented and uncontrolled online. For years the owners had been known for their passion and love of their business, but they had struggled to produce a Web site that would support their loyal fans as well as perpetuate a brand that would speak to new prospective customers.

Their problems sat with an incomplete vision of their online audience and potential reach. Their Web site spoke to current brand enthusiasts, however it could not provide enough of a forum for their fans to express their devotion. As such, YouTube videos, blogs, unofficial Facebook fanpages, etc., were appearing across the Internet and were, in many cases, pulling away from the core values and mission of their business.

Additionally, unless a prospect knew to search for their specific company name or slogan, they would not find any official Web sites in search results.

How do you build and “feed” a community of loyal customers to continue to build your brand from the inside out as well as open the market and build brand awareness to new, valuable prospects?

Sometimes you need to go big or go home! So in an effort to establish your online brand, sometimes you have to decide to redesign your Web site, rewrite all the content for SEO (search engine optimization), and start aggressively utilizing social media to congregate followers! It can be a big job with a big payoff.

Tip #1: Love your domain name and show

the search engines you care: Select a domain name for “findability” – it matters!

38 | May/June 2010

What is your current domain name? Does it reflect who you are and what you do? Does it reflect how your customers are trying to find you? Does it include any of your key words for SEO?

Tip # 2:

Build new Web site look and feel consistent with mission.

Does your old site lack focus with too much going on? The example company included over 60 “options” immediately of what the user could do, so essentially the clear action for a user to take was “do everything … now.” Also, their homepage would be used as a clearinghouse for products on sale, giving them the image of being the Wal-Mart of their industry. People who came to the homepage who needed help with a specific subject would have to search over several pages to find the answer. It was very confusing and not consistent with their message.

Their new site has cleared out the clutter and cuts to the chase. Four primary conversion opportunities are presented on EVERY page of the Web site. Additionally, their background is consistent with their other product lines on the homepage and every interior page. The goal is to present a cohesive user experience that appeals to both the long-time devotee, as well as the first-time visitor looking for guidance.

Tip #3: Set up social media for huge com-

munity of followers waiting for your lead.

Have you established a social media presence?

Large communities of devoted followers are building their own Facebook pages and are looking for someone like your company who already has a presence. Establish “THE” credible, official place on social media sites your followers can trust.

Taking the dive and reinventing yourself or your business is scary, but even scarier is the inability to adapt and change over time. The Internet is a very fast-paced environment, and you must stay in touch with mistakes you may have made in your branding and be willing to make it right.

Ultimately, you’ll see big payoffs and great findability for being bold and taking a stand for who you are as a company.

About the Author: Heather Lutze has spent the last 10 years as CEO of The Findability Group, formerly Lutze Consulting, – a Search Engine Marketing firm that works with companies to attain maximum Internet exposure. For more information, visit www.FindabilityGroup.com. www.ifps.org | www.fluidpowerjournal.com

ProductReview

Classifieds

Fluid Power, Inc. Currently has an opportunity for a motivated, organized, and self-disciplined hydraulic systems mechanic. Position responsibilities include:

Ultrasonic Diagnostic Instrument Spectronics Corporation

The Spectroline® Marksman™ ultrasonic diagnostic tool converts and amplifies inaudible ultrasonic sound into audible “natural” sound to signify problems such as compressed air leaks, electrical discharge, as well as vacuum, natural gas, propane, refrigerant, seal and gasket leaks. The kit comes with a receiver, full-sized headphones, two probes, and an ultrasonic emitter that allows technicians to test for faulty seals, gaskets, and weather stripping in doors, windows, ductwork, and other unpressurized enclosures. www.spectroline.com

Œ

Piston Pumps with Hydromechanical Torque Control Eaton Corporation

• Assembly and testing of hydraulic power units, manifold assemblies, and actuator assemblies.

• Setting pressure and flow parameters of hydraulic valve elements.

• Repair and rebuilding of hydraulic, pneumatic, and lubrication equipment • Prototype product testing and evaluation.

Compensation is commensurate with qualifications and experience, and includes health benefits.

215-643-0350 www.fluidpowerinc.com

A hydro-mechanical torque control option and several performance upgrades have been added to the 420 open circuit piston pump product line. The 420 pump with hydro-mechanical torque control automatically senses heavy loads and adjusts hydraulic fluid flow accordingly.

It is intended for moderate-flow, medium-pressure mobile applications such as compact wheel loaders, telehandlers, rough terrain forklifts, telescopic booms, sweepers, backhoe loaders, and refuse trucks operating up to 280 bar continuously. The pump housing has been redesigned and a caseto-inlet check valve has been added to improve cold weather operation and provide added protection to the seals and rotating group. Other design changes have decreased airborne noise to a typical 76 dBA at 1800 rpm and 207 bar. www.eaton.com

Ê

Two-Way Solenoid Valve Assured Automation

The J Series solenoid valve is a pilot assist design offering high flow rate with minimal pressure loss and features a spring return design that is “fail open” or “fail close” upon loss of electrical power. Cycle speed is fast, occurring in as little as 0.25 milliseconds in either direction. The pilot assist design only requires a 3-psi differential on either side of the valve. The valves are available in 2-way configurations, 3/8" to 2" with pressure ratings up to 225 psi (150 psi max for steam).

Valve bodies are brass with BUNA and EPDM diaphragms. End connections are FNPT. Coils are DIN connectors with cord grip. www.assuredautomation.com

Œ

www.ifps.org | www.fluidpowerjournal.com

May/June 2010 | 39

Classifieds

May/June FPJclassified2010:Layout 1 11/11/09 4:18 PM Page2010

Surplus Inventory Wanted We pay top dollar for surplus inventory and are always looking for: Hydraulics Power Transmission Pneumatics Electric Motors Engines Wheels & Casters

SURPLUS CENTER

1015 West O Street, Lincoln, NE 68528

Fluid Power Executive Recruiters As veteran recruiters who focus in the Fluid Power Industry, we need outstanding professionals to fill opportunities in: -Engineering -Design -Manufacturing -Sales -Marketing Contact: Eric C. Bergsman, Sales/Marketing Dave Sevel, Engineering William Radke, Manufacturing/Operations Marvel Consultants, Inc. 28601 Chagrin Blvd., #210, Cleveland, Ohio 44122 www.marvelconsultants.com recruiters@marvelconsultants.com Tel: 216-292-2855, Fax: 216-292-7207

27

HYDRAULIC FLANGES and COMPONENTS THE “SPECIAL” YOU WANT IS PROBABLY ON OUR SHELVES

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5 CIL-MM14 FPJ 1/27/10 9:58 AM Page Yuken......................................................................................... 17 Ad • Web Marketplace • Product Spotlight • Software Showcase

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