Fluid Power Journal November/December 2010

State of the art

Fluid Power Products

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contents November/December 2010

•

Volume 17

•

Issue 10

Features

12 13 16 18 20 The Perfect Hydraulic Fluid: Part II

By Brendan Casey

What in the World Do Those Numbers in the

ISO Cleanliness Code Mean?

By Dan Helgerson, CFPAI, CFPAJPPCC, CFPMT, CFPCC, CFPS Cascade Steel Rolling Mills, Inc.

24 27 Vacuum Clampıng

By Daniel Pascoe Vacuforce, Inc.

RELIABLE PLANT 2010

Conference is Major Success

Gives Realistic Ride Courtesy of Smooth Electrohydraulic Controls

By Peter Nachtwey, Delta Computer Systems, Inc.

departments

24

Pneumatic Theatrical Kits

Fill Need for Low-Budget, High-Impact Special Effects

By Mickey Henry, Norcostco

IFPS Annual Meeting and 50th Anniversary

Six-Axis Motion Simulator

28

4 5 6 7 8 9 26 30 33 38 39 39

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

Official Publication of The International Fluid Power Society

Get Inspired.

Get Connected.

Get Moving.

C

M

Y

CM

MY

CY

CMY

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STAY AHEAD OF THE TECH CURVE Learn the “next thing coming� solutions to integrate now into your design applications. Over 100 education presentations will focus on the newest technologies, research and developments for the fluid power, power transmission and motion control industries.

All in one place, once every three years.

Register Now: IFPE.com

Las Vegas, USA

March 22-26 Co-owned by the National Fluid Power Association and the Association of Equipment Manufacturers.

Request more information at www.fluidpowerjournal.com

NotableWords 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

You

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

are not here merely to make a living. You are here in order to enable the world to live more amply, with greater vision, with a finer spirit of hope and achievement. You are here to enrich the world, and you impoverish yourself if you forget the errand.

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

This quote by Woodrow Wilson really resonated with me a few weeks ago as I participated in the International Fluid Power Society’s 50th anniversary celebration in our nation’s birthplace, Philadelphia, Pa. It was hard not to think about all the people who, over the past 50 years, gave his or her time to the growth of this Society – who, in the words of President Wilson, enabled the Society to live with a finer spirit of hope and achievement. It was even more inspiring to see 70 volunteers come together to keep the vision of the original IFPS founders alive. And alive it is! While the rest of the world is just beginning to see a slight rebound from the economic Donna Pollander (middle) with past executive turmoil of the last couple of years, the directors Jim Morgan (lef IFPS is strong, solid, and thriving. t) and Paul Prass (right) at the IFPS 50th anniver On a personal note, I would like to sary celebration say that I was so humbled to meet nine of the Society’s past presidents and hear their experiences from when the IFPS was just starting out. It was especially gratifying to see their pride as they got to see first-hand how their Society has matured since the 1970’s and 1980’s – serving over 10,000 people who work in and around the fluid power industry. I am also so happy to serve the current leadership as they work toward an even brighter future for the IFPS. This Society has no intention of resting on its laurels. In fact, even as they celebrated their 50th anniversary, the IFPS leadership held a strategic planning session to ensure that the Society continues to move forward and work hard.

So thank you, IFPS, for the opportunity to be a part of such a progressive, positive organization! I look forward to nurturing the greater vision of this Society, and I look to the future with hope and achievement!

Donna Pollander IFPS Executive Director

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

CORRECTION: In the article “Maximum Recommended Compressed Air Flow in Pipes” in the September/October issue: 1. Equation 12 on page 13 should be Nr = 127.1 (Q­o / di) 2. List item D on page 13 should be “Friction factor calculated from Colebrook Eq. using e=0.00015 ft.”

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.

4 | November/December 2010

www.ifps.org | www.fluidpowerjournal.com

C elebrating 50Years

IFPS Time Capsule

The International Fluid Power Society

1991: The Mechanic Certification test was released and divided in two

stages: Mechanic I and Mechanic II, featuring separate tests for hydraulics and pneumatics. The first group of individuals became Accredited Instructors with the FPS. 1992: Industrial Hydraulic, Mobile Hydraulic, and Pneumatic Mechanic certifications and the Job Performance testing began development, and the first FPS Certification Directory was published. Three fluid power occupations were officially recognized by the U.S. Department of Labor in its Dictionary of Occupational Titles (D.O.T.). The FPS Headquarters moved to Bethlehem, Pa. 1993: Pneumatic Mechanic manual and certification test were released.

The Engineer certification was developed and has since transformed into today’s CFPE certification.

1994: The Mobile Hydraulic Mechanic and Pneumatic Mechanic certification tests were released. The 2,000th fluid power professional was certified (Richard E. Hunn, B&T Hydraulics, earned the Fluid Power Specialist certification). The 1994 FPS Certification Directory was released showing an increase of 50% from the previous year’s edition and included 2,171 certified professionals and 428 employers. The Fluid Power Journal was launched.

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

1998 &1999: The Specialist certification split into separate certification tests for Hydraulic Specialist and Pneumatic Specialist; the Hydraulic Specialist test and Job Performance test were revamped and re-released.

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

2002: FPS elected its first female president of the Board of Directors: Lisa Reeve , Hydraulic Technology, LLC. 2003: FPS hired IDP Association Management, and the FPS Headquarters moved to Cherry Hill, New Jersey.

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

2005: The FPS officially adopted “International” as part of its name, becoming the International Fluid Power Society (IFPS).

2007: The Raymond Hanley Certification Endowment Fund was established for technology training for IFPS Accredited Instructors.

The IFPS Board voted to reserve $400,000 to review and update all existing certifications.

2008: The IFPS Certification Directory listed 9,529 active certifications, and the Electronic Controls Specialist certification began development.

2009: The Electronic Controls Specialist certification was released, and the groundwork for the Mechatronics certifications began. The IFPS/ First Scholarship was established granting two $2,500 scholarships to high school students who used pneumatics on their 2009 FIRST Robotics Competition robots. The IFPS listed nearly 4,000 members and 10,000 active certifications.

2010: The IFPS celebrated its 50th Anniversary with a newly re-designed Web site. The Mobile Electronic Controls and Industrial Electronic Controls certifications began development.

Source: IFPS Web site (www.ifps.org)

“I got involved with the Fluid Power Society as a young man while pursuing my Mechanical Engineering degree at Purdue University by becoming a member of the student chapter in 1979 with special thanks to Professor Banton. I continued as a member, and then early in my career while working at Rexroth, I became involved with the local Lehigh Valley Chapter in Pennsylvania, first as a participant and then going through the chairs. Many thanks to Tom Frankenfield, Larry Shea Jr., and Don Piper for all their help with the chapter through the years.

I then became involved with ‘National’ and served on the Board of Directors running through various chairs and developing a Membership Directory and Annual Report in 1991, which continued for years, along with Certification Directories. Special thanks to Alfred Krug of Rexroth for supporting my involvement.

My wife Lisa and I were then asked by the Executive Committee to start the Fluid Power Journal in 1993, and then I was asked to take over the helm of the new “International” Fluid Power Society in 1995 as the Executive Director, which continued until 2004 when it was passed to the very capable Donna Pollander.

Throughout it all, I am most impressed by the people that I had the opportunity to meet and work with. They are some of the best and most sincere people with awesome character! Two folks that have given much to the organization are Ray Hanley and John Groot. The list of folks I had the honor of working with and knowing is incredibly long, and I feel very privileged to have been able to contribute to the IFPS. The work of IFPS is still in its infancy, but we have accomplished great things together! Membership networking opportunities, Certification setting industry standards, the Fluid Power Journal, Industry Education, Professionalism, etc. I’m very proud of the people and the work that they have accomplished on behalf of the Fluid Power Industry.”

– Paul F. Prass, CAE IFPS Executive Director 1995-2004, Publisher, Fluid Power Journal

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November/December 2010 | 5

AllAboutAir

T

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

Reynolds Number, Laminar Flow

he amount of energy used is a common topic, and many feel that an urgent need to reduce energy consumption and efficiency is usually a good thing. In the August issue of Plant Engineering magazine, the article “Air Apparent” starts with this: “According to the U.S. Department of Energy, compressed air systems can account for as much as 30% of a plant’s total energy consumption.” For a utility of this proportion, compressed air seems to be taken for granted, and many compressed air systems “just grow up” rather than being crafted from a master plan. In some cases, published “Best Practices” are touted that could not be defended.

Making products faster to increase productivity seems to be on many minds.

As manufacturing strives to increase output and productivity, then more automation, machinery, and air are often required. Speeding up the process may increase the use of compressed air in a system that has long since exceeded optimum flow through pipes.

The amount of flow in compressed air plumbing, originally undersized from charts that are over-stated, become worse as flow demand increases through organic growth and/or the need for speed.

In 1833, Osborne Reynolds developed a formula for flow rates that gave a number to indicate the velocity of the flow. Another item of interest was the change in flowing fluid from laminar to turbulent. It is widely accepted that air flow is laminar for Reynolds numbers of 2000 or less. Flow between 2000 and 4000 is undermined and may be either laminar or turbulent. Above 4000, all air flow is considered to be turbulent. Laminar flow typically has low-pressure drop.

Turbulent flow causes high-pressure drop and agglomerates aerosol of oils that might otherwise travel further and provide lubrication.

There are no drawbacks to oversizing the plumbing in a compressed air system. Higher initial cost is a one-time expense that will be paid for many times over by the benefits.

I am going to provide some tools and formulas that will help you determine • the maximum flow to use with any pipe or tube when you know the inside diameter of the plumbing and the operating pressure • the pipe size and inside diameter based on the flow and operating pressure • the Reynolds Number with the flow velocity, inside diameter, and pressure known The Reynolds Number formula is simplified in the laminar zone. The formulas that follow are standard with constants crunched and will help you with laminar flow.

Reynolds number at 2000 was used for items 1 and 2, 1. Find Maximum Recommended flow.

D2(in) x 9.93 x [(P psig + 14.7psia) / 14.7] = Q scfm 2. Find pipe size, ID. [Qscfm x 14.7psia / (9.93 x (P psig + 14.7psia))]1/2 = D in 3. Find Reynolds Number.

Re = (V f/m x D in x 8.573) / ((P1 psig + 14.7psia)/ 14.7psia)

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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

FigureItOut

Previous Problem:

Sluggish Polishing Machine for a Casket Manufacturer (from Tech Directory 2010 issue) A casket manufacturer has a machine that polishes the stainless steel exterior on finished caskets to a fine “brushed” look for one design that’s very popular. The polishing head is powered by a “servo valve” hydraulic system that allows them not only to vary the speed of the turning brushes but also maintain the force exerted on the brushes. The servo valve electronic controls incorporated a feedback signal from the hydraulic motor to assure a constant RPM speed for the brushes regardless of the pressure applied.

This process has been in place for 10 to 15 years, and other than obvious maintenance fixes, it worked well. The workers did a good job of maintaining the ISO cleanliness code and temperature of the hydraulic oil. Oil samples always came back reflecting the good maintenance practices they had in place.

However, a problem developed where the maximum brush RPM’s could not be reached and maintained, even though the circuit for advancing and applying pressure worked just fine. (See the accompanying circuit.)

The coils of the servo valve were wired in parallel, and when the resistance of each was measured, they both appeared to be fine. The workers checked the signal coming out of the amplifier card controlling the servo valve, and it also seemed fine. They then replaced the servo valve with a new one after checking the continuity of the cable going to the valve.

The system would work fine part of the time but not consistently. Any idea what could be wrong?

Brush Force Brush RPM

Solution Servo valves have two coils that control the tilt of the torque motor. When wired in parallel and properly wired in relation to their polarity, the coils can produce enough force to fully stroke the valve. However, if one coil is “open,” the valve only has half the force stroking the torque motor and cannot fully open, reducing the maximum flow capacity and also slowing down the response time of the valve.

The fact that it worked fine part of the time would indicate the hydraulics was not the problem. I found that if the cable feeding the valve was moved to a certain position and held there, the system worked fine. Closer inspection of the cable, where it interred the connector and was soldered to the connector terminal, found the solder joint of one wire was a “cold joint” and the wire separated from the terminal when the cable was bent one direction. Resoldering the wire to the terminal solved the problem.

1500 PSI

1650 PSI Water Supply

Stainless Plate Mill Straightener System Follow Up (from the September/October 2010 issue) The article on the “Stainless Plate Mill Straightener System” problem in the September/October issue generated a lot of e-mails. Most questioned why the pilot-to-open check valve on the rod side of the cylinder did not keep the cylinder from “running away” from the pump flow that caused the cap end cavitation.

The redesigned system was all-new components except for the cylinders, PO checks, and cap end reliefs. The cylinder pistons were checked for leakage and proved to be in good condition as well as the 9000-psi relief valves.

However, the PO check valves all leaked.

Maintenance workers rebuilt the PO check valves with factory-supplied kits, but they still leaked when tested. They thought they could increase the closing force and stop the leaks by adding spacers behind the check valve spring.

However, the stronger spring force did not help.

We were asked to help them fix the PO checks and troubleshoot the system.

We showed them how to “coin” the ball into the seat on the PO checks. This was done by using a solid brass rod with a diameter that just fit into the bore where the ball would slide and then strike the brass rod with a hammer driving the steel ball into the seat, stopping the leaks. This procedure is commonly used by repair houses that specialize in repairing hydraulic jacks and lifts. www.ifps.org | www.fluidpowerjournal.com

The PO check valves also had a 6.5-to-1 pilot ratio. Basically, this means if the check ball is held in place with a cylinder load of 1000 psi, it only takes pilot pressure slightly more than 1/6.5 of this pressure (154 psi) to open the check— provided the 154-psi pilot pressure was not applied to the cap end before the rod check opened.

Without the rod side meter-out flow control, the cylinder extension speed was being controlled by the 3/8" OD steel tubing, directional valve, manifold, hoses, and return line filter pressure drop. The cylinder extension speed was faster than the pump supply, causing cavitation while the cap end check valve spring provided enough pilot pressure to keep the rod side PO check open.

Adding the flow control to provide additional back pressure kept the cylinder extend speed slow enough to prevent cavitation. Now the cylinders would hold their position.

One thing that continues to amaze me is the odd things that defy good acceptable circuit design. These odd things help to keep you sharp and on your toes anytime you’re called to troubleshoot or debug a system.

November/December 2010 | 7

MathTeasers

This Issue

with Professor P.V. Btfsplk

New Problem: Hydraulic Pump A 5-cir hydraulic pump is operating at 1200 psi and delivers 28 gpm at a speed of 1800 rpm. It has a 25-hp prime mover (electrical motor). Please find the mechanical efficiency of the hydraulic pump? __________%

Previous Problem: Pneumatic Accumulator (From September/October 2010 Issue)

What precharge pressure is needed when 4.45-gallon of oil is needed from a 10-gallon accumulator?

Given: P2 = 3000 psi T1 = 700°F Illustration: John Spisak

T2 = 1250°F P2 = 3000 psi +14.7 = 3014.7 psia V1 = 10 gallons V2 = 10 gallons – 4.45 gallons = 5.5 gallons T1 = 700°F + 460 = 1160°R T2 = 1250°F + 460 = 1710°R P1 = P2 x V2 x T1 / V1 x T2 = P1 = (3014.7) (5.55) (1160) / (10) (1710) =

Winner Jeff Curlee CFPPS Production Systems, Inc. High Point, NC Answered Correctly Ernie Parker CFPAI, CFPMM, CFPMT, CFPS, CFPCC Mukwonago, WI Jason Moore CFPS Parker Hannifin Norfolk, VA

Philip Lane CFPS Vermeer Corporation Pella, IA Tri Nguyen Plymouth, MN Ryan Roberts CFPHS Eaton Hydraulics Eden Prairie, MN Scott Brown CFPHS Hydraulic Supply Company Augusta, GA

1135.3 psia – 14.7 = 1120.6 psig 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 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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November/December 2010 | 9

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November/December 2010 | 11

Part II by Brendan Casey

Y

ou may have done this experiment at school: your science teacher gives you a plastic syringe. With the plunger retracted, she tells you to block the outlet with your finger and then attempt to close the plunger. You discover you are able to compress the air in the syringe by a significant amount.

She then tells you to repeat the experiment with the syringe full of water. This time the result is very different. No matter how hard you try, you discover you can’t compress the water in the syringe.

Seeing is believing. And to a 12-year-old, this experiment demonstrates, quite dramatically, that gases are highly compressible and liquids are apparently incompressible. By the way, if you didn’t do this experiment at school, you can try it at home!

The effectiveness of this simple physics experiment is illustrated by the fact that in my work as a fluid power engineer, I regularly meet people who believe liquids, including hydraulic oil, are incompressible. But it’s not their fault. I certainly don’t remember my science teacher qualifying the obvious results of this experiment by explaining that compared to gases, liquids are highly incompressible but compressible nonetheless!

In my previous column, I talked about the perfect hydraulic fluid with respect to viscosity. This ideal fluid would have a constant viscosity of 25 centistokes, regardless of its temperature. Another property of this ideal but non-existent hydraulic fluid would be perfect stiffness—just like the apparent stiffness of the water in the syringe in our school science experiment.

A fluid’s compressibility is defined by its bulk modulus of elasticity, which is the reciprocal of compressibility. The bulk modulus of a fluid is non-linear, meaning when the change in volume with pressure is plotted on a graph, the result is a curve rather than a straight line.

Bulk modulus is further defined as isothermal— where the heat associated with compression is dissipated (constant temperature) or isentropic— 12 | November/December 2010

where the heat associated with compression is not dissipated and so both pressure and thermal expansion are considered. Isentropic can be thought of as dynamic bulk modulus and isothermal as static bulk modulus. The former is most pertinent to modern, high-response hydraulic systems.

The Negatives of Compression

Bulk modulus is an inherent property of the oil and therefore an inherent inefficiency of the hydraulic system. The fluid in the pipeline and actuator must be pressurized—and therefore compressed—before it will move a load. Because this compression of the fluid requires work at the input, which cannot be converted to useful work at the output, it is lost work and therefore a contributing factor to the overall inefficiency of the hydraulic system. The larger the actuator and the faster its required response time, the higher the inefficiency attributable to bulk modulus.

And in high-performance, closed-loop electrohydraulic systems, deforming oil volumes affect dynamic response and can cause stability problems such as self-oscillation.

Minimizing the Losses

Bulk modulus varies with base stock. For example, naphthenic oils have a higher bulk modulus than paraffinics. And unlike viscosity index, bulk modulus cannot be improved with additives. But there are things we can do to minimize the inefficiencies and potential control problems associated with compression of the fluid.

The first is to ensure the hydraulic machine doesn’t run hot. Compressibility of the fluid increases with temperature. Mineral hydraulic oil is around 30% more compressible at 100°C than it is at 20°C. Of course, there are many good reasons why you should never allow hydraulic equipment to run hot—many of which I have discussed in previous articles. Reduced bulk modulus is another one.

The second is to prevent conditions that cause aeration. From our school science experiment, we understand that air is 10,000 times more compressible than oil. One percent of entrained air by volume can reduce the isothermal bulk modulus of the oil to as low as 25% of its normal value.

It is important at this point to distinguish between entrained air—bubbles typically with a diameter of less than one millimeter dispersed through out the fluid—and dissolved air. Hydraulic oil typically contains between 6% and 12% of dissolved air by volume.

This dissolved air has no measurable effect on bulk modulus (or viscosity)—provided it stays in solution.

While controlling aeration is in no small part a design issue—for example, the amount of dwell time the fluid has in the tank—proper maintenance also plays an important role. Dissolved air comes out of solution as temperature increases. This is another reason to maintain appropriate and stable operating temperatures. Oxidative degradation and water contamination inhibit the oil’s ability to release air, often resulting in an increase in entrained air volume.

Conclusion

Given the perfect hydraulic fluid—one with infinite stiffness—does not exist, and in view of the current trend towards hydraulic equipment with higher operating pressures, higher power density and faster response, it’s more important than ever to consider the operational effects of fluid compressibility on the hydraulic equipment you design, operate, repair, or maintain.

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. www.ifps.org | www.fluidpowerjournal.com

What in the World Do Those Numbers in the ISO Cleanliness Code Mean?

By Dan Helgerson

e have been talking a lot about filtration here at the steel mill. My predecessor, Scott McLoughlin, had done a remarkable job in educating by example, demonstrating the need for good control of the fluids in our hydraulic and lubrication systems. He had helped stop the leaks and had added well thought-out filtration systems that have resulted in substantial savings and increased productivity. There is still a lot of work to be done, and in pursuing that, we have invited a number of vendors in, each offering an approach to getting and maintaining an acceptable fluid cleanliness level. The one thing they all have brought to the table is a discussion of the ISO cleanliness code. I was in a meeting with a group of managers when one vendor began to talk about the code. Being a Certified Fluid Power Accredited Instructor (AI), I immediately saw this as an obvious teaching moment, so I asked, “Does anyone here want to know what those numbers mean?” The answer was a quick and resounding, “No!”

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November/December 2010 | 13

What in the World Do Those Numbers in the ISO Cleanliness Code Mean?

Now, if you are a fluid power professional or aspire to be one, you do not have the luxury of willful ignorance. The ISO cleanliness code is the industry standard, and we ought to know what it means. This article becomes my replacement teaching moment.

The industry has known for a long time that contamination is the major cause of failure in fluid power systems. The challenge has been to come up with a standardized method of measuring and describing the cleanliness of the fluid and then to establish guidelines for determining just how clean the fluid ought to be for a given system.

Having a filter, even the best filter, does not ensure clean fluid. If the filter is bypassing or in the wrong location, it will not protect the components. The only way to be sure of the contamination level of the fluid is to take a sampling of the fluid as it moves through the system. It is important to get the sample out of the working fluid because fluid that is at rest, like in the reservoir or during a shut down, will not give an accurate picture of what is happening dynamically.

We also need to understand something about contamination. It is not like there are a bunch of little tiny ball bearings of uniform shape and size in the fluid.

Contamination is the debris resulting from wear, assembly, dust in the air, and/ or anything else that can break loose and be caught up in the fluid stream. The particle sizes range from itty-bitty to big chunks, and the shapes are irregular.

It was found that, by looking at particles in three different size groups and then seeing how many of those particles were in a specific volume of fluid, we could make an evaluation of the overall condition of the fluid. The sizes chosen are 4, 6, and 14 micrometers. Micrometers are also referred to in terms of microns and use the symbol µm. The volume of fluid to be sampled is 100 ml (a little less than ½ cup).

It is important to note that these are very small particles, all of which are smaller than can be seen by the unaided human eye. We can see particles that are as small as 40 µm. The stuff we are talking about is 3 to 10 times smaller than anything we can see. A red blood cell is about 8 µm in size, and when was the last time you could pick one of those out in a crowd?

A fancy machine looks at the sample and counts the particles it sees. This is where it starts to get fuzzy, so hang on. We are not given the actual particle count.

Instead, the count is described in terms of how it relates to the factor of 2. For example, if there were 512 counted particles in a 100-ml sample of fluid, there would be 2 x 2 x 2 x 2 x 2 x 2 x 2 x 2 x 2 (or 29) number of particles and we are given the number 9 as the count.

I see some of you just dropped out. It’s really not that bad. Take a moment and read the last paragraph again, slowly…ok, now, do you understand what the number 9 represents here? That’s right! It is the number of times 2 would be multiplied by itself to equal the particle count. Now, I don’t pretend to know why this approach was chosen, but it is what we have to live with.

But wait! There’s more. The number 9 does not mean that there are 512 particles that were counted. It means that there were between 28 and 29 particles counted or somewhere between 256 and 512 particles. Adding another layer of complexity, what is published is the maximum contamination level expected to be found in only 1 ml (1/100th) of the sampling. So, when we look at the data, we are to understand that the 9 means that we can expect to find between 2.5 and 5 counted particles in every 1 ml of fluid. Huh???

14 | November/December 2010

I can repeat that but instead, let me give you an example. Let’s say we have a test result that shows a cleanliness level of 17/13/9. What does that tell us, exactly?

Well, it doesn’t “exactly” tell us anything. What it gives us are two categories for describing the cleanliness of the fluid. It provides information on the size and quantity of particles in the system. The first number represents the range of particles that are 4 µm (micrometers) or larger in 1 cc (1 ml) of a sample fluid but not a precise number of those particles. The first number will never be smaller than the second number, and the second number will never be smaller than the third number because each number includes the particles in the next group.

The second number represents the range of particles that are 6 µm and larger.

The third number represents the range of particles that are 14 µm and larger.

Remember, the number is the power to which 2 is multiplied. That result is then divided by 100 and rounded a little bit to give the maximum number of particles of a certain size and larger that you would expect to find in 1 cc (1 ml) of fluid. The actual particle count would be somewhere between ½ of that number and that number.

In a 17/13/9 result, we have a particle count, including all sizes 4 µm and larger represented by 17. That means we have a maximum number of particles 4 µm and larger of 217/100. 217 = 131,072. If we divide that by 100, we get 1,312. So the maximum number of particles 4 µm and larger in the 1 cc sample would be 1,300. (Remember the rounding?) The minimum number of particles 4 µm and larger would be 216/100 or 655 (but because of the rounding, the number used is 640). The bottom line is that the 17 tells us that we have somewhere between 640 and 1300 particles 4 µm and larger in a 1 ml sample.

Continuing, the 6 µm and larger particle count is represented by 13 so the number of particles 6 µm and larger is somewhere between 212/100 and 213/100. 212 = 4,096. If we divide that by 100, we get 41ish. 213 = 8,192. When we divide that by 100, we get 82ish. So the total number of particles in the 1 cc sample 6 µm and larger would be anywhere between 40 (Remember the rounding?) and 80.

The 14 µm and larger particle count is represented by 9, so the number of particles 14 µm and larger is somewhere between 28/100 and 29/100. 28 = 256.

If we divide that by 100, we get 2.5ish. 29 = 512. When we divide that by 100, we get 5ish. So the total number of particles in the 1 cc sample 14 µm and larger would be anywhere between 2.5 and 5.

This is where we need to be careful. The difference between 17/13/9 and 18/13/9 could mean as many as 1,200 more particles or it could mean just 1 more particle. That is why it is important to get sampling over time.

Table 1 shows the code numbers and what they mean. The number color matches the highlighted row on the table.

Table 1: ISO Code 17/13/9 Code

2 to Code Power

Actual Particle Count

6

64

From 0.32

To 0.64

7

128

0.64

1.3

8

256

1.3

2.5

9

512

2.5

5

10

1,024

5

10

11

2,048

10

20

12

4,096

20

40

13

8,192

40

80

14

16,384

80

160

15

32,768

160

320

16

65,536

320

640

17

131,072

640

1,300

18

262,144

1,250

2,500

19

524,288

2,500

5,000

20

1,048,576

5,000

10,000

21

2,097,152

10,000

20,000

22

4,194,304

20,000

40,000

23

8,388,608

40,000

80,000

24

16,777,216

80,000

160,000

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Now that we have a way of describing the contamination level, how do we determine what the level ought to be? Different components have a different tolerance for contamination. A system with a gear pump, poppet valves, and cylinders will not require the same cleanliness as a system using piston pumps, servo valves, and piston motors. Studies were done to determine the cleanliness level required for various fluid power components. This resulted in Table 2, which helps us know how clean a particular system needs to be. We can now set a target cleanliness level based on the contamination tolerance level of the most sensitive component in the filtered fluid stream. We can also isolate and target super sensitive components and provide them with their own dedicated filtration systems.

Table 2: Target Cleanliness Level for Components at Various Operating Pressures PUMPS

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he flange lock tool from Flange Lock LLC in Greenwich, Conn., is an easy-to-use cap that slides onto the fitting and is sealed with one turn of the bottom plug, keeping oil in and contaminants out. It is produced in sizes for 8, 12, 16, 20, 24, and 32 in codes 61 and 62.

It is currently being manufactured in aluminum.

Company founder Greg Molloy used his knowledge of attachments and flange lines to develop this product in response to requests to stop leaking lines. It can be used in industries such as construction, oil fields and dredging applications, wind turbines, and large machine tools—just about in any field where flange end lines are used and where oil leaks are a concern.

According to Mike Pearl, part owner of Flange Lock LLC, the tool will save time because there won’t be any leaking oil to clean up, which means no wasted oil.

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This information was taken from the Certified Fluid Power Electronic Specialist Study Manual dated 12/18/09, and is found on page 10-30.

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

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November/December 2010 | 15

By Paul V. Arnold, Editor-in-Chief, Noria Publishing

RELIABLEPLANT 2010 Conference is Major Success Industrial professionals from around the world attended RELIABLE PLANT 2010, Noria’s annual conference and exhibition, held August 30-September 2 at the Nashville (Tenn.) Convention Center. Attendees represented companies in 44 states and 21 countries. This year’s event included three co-located trade shows: Lubrication Excellence, Reliability World, and Lean Manufacturing.

RELIABLE PLANT 2010 marked the 11th year of Lubrication Excellence, the sixth year of Reliability World, and the fifth year of Lean Manufacturing.

The event was sponsored by CITGO Lubricants, Des-Case Corporation, Emerson Process Management, HYDAC, Hy-Pro Filtration, Lubrication Engineers, Schroeder Industries, Shell, SKF, and Snap-on Industrial. It was endorsed by the International Council for Machinery Lubrication (ICML) and the University of Tennessee Reliability and Maintainability Center.

During the three main days of the conference, August 31-September 2, more than 75 case studies, industry reports, and training sessions were presented.

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August 31. Track keynotes were presented by: Samuel Bethea, the director of North American maintenance and reliability at Campbell Soup Company; Aqua Porter, the vice president in charge of strategic projects and Lean Six Sigma operations at Xerox Corporation; and Robert Hafey, the author of the new book “Lean Safety – Transforming your Safety Culture with Lean Management”.

Lubrication Excellence presentations were delivered by leaders from: Noria, MillerCoors, Eli Lilly, ArcelorMittal, Energizer, Goodyear, Temple-Inland, Alabama Power Company, Covance, Shell, ICML, Lubrication Engineers, Polaris Laboratories, Schroeder Industries, Hy-Pro Filtration, Hendrix Engineering, Ludeca, Pioneer Engineering, Pall Corporation, MRG Labs, Des-Case, CITGO, Reliable Process Solutions, Fluitec International, IDCON, Wooton-Consulting, Thermal-Lube, Air-Tight Hubs, Spectro/QinetiQ North America, and Lubrication Systems Company.

Reliability World presentations were given by leaders from: Alcoa, AnheuserBusch InBev, Campbell Soup, Frito-Lay, ITT, Wells Dairy, AEDC/ATA, SKF, Periscope Consulting, Infor, PdMA Corporation, SDT North America, Emerson Process Management, Laurentide Controls, UE Systems, Lubrication Engineers, UtilX, People and Processes, Sigma Reliability Solutions, SageGuides.com, Productivity Inc., Reliable Process Solutions, Spectro/QinetiQ North America, John Crossan LLC, and Manufacturing Solutions International.

Lean track presentations were given by leaders from: Xerox, Raytheon Missile Systems, Sonoco, Syngenta Crop Protection, APS, Sara Lee, Woodbridge Foam, RBH Consulting, Life Cycle Engineering, Future State Solutions, Gemba Consulting North America, Sigma Reliability Solutions, and the Lean Leadership Academy.

At the expansive exhibition hall, more than 70 suppliers featured new products and industry solutions.

Workshops from Jim Fitch of Noria (“How to Rate and Select Oil Filtration”) and Drew Troyer of Sigma Reliability Solutions (“How to Optimize Preventive Maintenance Plans”) took place on August 30. ICML held testing for its Machine Lubricant Analyst (MLA), Machine Lubrication Technician (MLT), and Laboratory Lubricant Analyst (LLA) certifications on August 30 and September 1.

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Noria’s 2011 conference and exhibition will be held April 19-21 at the Greater Columbus Convention Center in Columbus, Ohio. To learn more about this event as well as additional education and training events, visit these Web sites: • http://conference.reliableplant.com • www.noria.com • www.machinerylubrication.com • www.reliableplant.com Request more information at www.fluidpowerjournal.com

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November/December 2010 | 17

By Peter Nachtwey, Delta Computer Systems, Inc.

Six-Axis Motion Simulator

Gives Realistic Ride Courtesy of Smooth Electrohydraulic Controls To build a realistic motion simulator, you need lots of motion axes.

Many of the best are based on the concept of a Stewart platform, a mechanical device with six linear hydraulic actuators mounted on a level surface in three pairs (Fig. 1). The six motion axes can be enumerated as: x, y, and z (i.e., lateral, longitudinal, and vertical), in addition to pitch roll and yaw. In combination, they enable what is called a full-motion simulator. By extending or retracting selected hydraulic cylinders, the upper platform can be made to shift and twist to simulate the action of a moving object such as a soaring airplane. If the motion is timed precisely to coincide with a video of the environment being simulated, the observer/rider on the platform can get a very realistic traveling experience.

Fig. 1: A Stewart platform uses six linear hydraulic cylinders to accomplish full motion simulation. In the case of the amusement park ride described in this article, the theater is mounted on top of the platform.

Such an environment is the basis for a popular attraction at a well-known amusement park. In this case, on top of the Stewart platform is a theater with 60 seats. The patrons arrive and are seated, the show begins, and the “passengers” are treated to a soaring flight around the world.

Key to ensuring a realistic and pleasant ride is maintaining precise, smooth control of the six hydraulic cylinders that power it. And at up to 90,000 pounds, the simulator platform is a very large mass to move with precision. The amusement ride described above was originally constructed in the 1980’s—some 25 years ago, but was due for an upgrade. The control system in place since the simulator was first developed had become unreliable and hard to maintain for various reasons. For example the analog wire-wrapped circuit boards, run by a PC, had developed intermittent glitches, and the system documentation was poor. If there was a problem with the ride controls, amusement park maintenance personnel had trouble debugging it. Also, it was difficult and expensive to change the content of the ride, and hence it was done only rarely.

Due to these factors, amusement park management decided it was time for a control system upgrade, and they hired an industrial systems integrator to propose and implement a solution that would involve replacing the old ride controls with a new electrohydraulic motion controller. The controller had to meet the following requirements: • The new motion controller needed to support closed-loop positioning controls. A key requirement in order to produce smooth, safe motion is to use closed-loop control, with a very short loop time. The system integrator experimented with different loop times and found that the controller had to update the position of each of the six axes at least 200 times/second, or

2

Fig. 2: Delta’s RMC150 electrohydraulic motion controller can control up to 8 axes of motion simultaneously and provides a built-in Ethernet interface. Fig. 3a: Before tuning, the motion feedback (i.e., the actual motion) exhibits variations. Fig. 3b: After tuning, the actual motion tracks the target (i.e. estimated) values precisely (the red and blue plotted curves overlap) and the motion is smooth. Fig. 4: A Delta RMCTools plot indicating a well-tuned system of varying amplitudes over a series of cycles.

3a

the people riding on the simulator could sense vibrations coming from the periodic updating of the target positions for the hydraulic actuators.

• The controller needed to interface directly with linear position sensors for precise feedback, enabling accurate real-time computation of velocity and acceleration.

• The motion controller needed to control proportional hydraulic servo valves. In order for the motion of the axes to be smooth, the hydraulic fluid sent to the cylinders must be controlled by proportional valves, capable of an infinite range of settings. Since proportional valves were incorporated when the simulator was first built, the new motion controller needed to connect with these easily. Minimizing changes to the existing hydraulics would help keep costs down.

• The controller needed to control six axes at the same time. To coordinate the operation of six axes, it was much better to use a single controller that had multi-axis capability compared to multiple controllers, one for each axis.

• The controller needed to have high-quality software interface, configurability, and EtherNet/IP communications. A key requirement was the ability to service and reconfigure the system, requiring the motion controller to be easily programmable and to interface with a programming PC or PLC over a network.

The industrial integrator had some experience with servo controllers in the past, but he knew that servo controllers couldn’t handle the stringent requirements posed by the list. An Internet search led to Delta Computer Systems, Inc. of Battle Ground, Wash., a designer and manufacturer with more than a quarter century of experience with hydraulic motion controls.

The product selected was the RMC150, a programmable motion controller capable of controlling up to eight motion axes directly and able to perform control loops 1000 times/second (Fig. 2). The controller uses a special function called gearing to cause the motion of the six axes to follow target-positioning commands delivered to the controller over EtherNet/IP by a PLC. (The simulator amusement ride has three main controllers, each having a key role: the motion controller, a safety controller with programmable interlock, and a PLC that communicates with the motion controller, directing the motion.)

Before the show starts, the PLC downloads a sequence of target positions for each axis into a data table in the motion controller at the rate of 200 entries per second. After it is given the command to start, the controller sequences through the target positions for each axis simultaneously. This arrangement, with the motion controller using gearing to follow a set of command inputs, also allows the simulator platform to be positioned in real-time using a joystick for maintenance purposes. www.ifps.org | www.fluidpowerjournal.com

3b

4

The motion controller also provides the ability for simulator ride designers to write custom user programs to perform special functions. For example, by checking for velocity and acceleration limits while the motion is occurring, the motion controller can cause the system to avoid conditions that would be uncomfortable or even dangerous for ride passengers. Further, to ensure that the motion of the simulator is smooth, without discontinuities, the motion controller can be programmed to examine the tables of motion target data that have been downloaded into the motion controller and filter the target motion values using a technique such as moving averages to smooth out the motion. If problems with the contents of a motion target array are detected during system testing, an external PC can be used to tweak array elements and reload them into the PLC. To tune the control loop gain parameters that affect how the motion controller responds to position feedback, Delta Computer Systems’ RMCTools Plot Manager is used for making plots of the motion. The plots show graphically at a glance when the system is not tuned correctly. For example, when the first set of control loop gains were used in the design of the ride simulator described above, the system was too responsive and the motion platform would shake (Fig. 3a).

After the control loop gains were adjusted with Delta’s automated tools to make the system respond less aggressively to position inputs, the motion smoothed out completely (Fig. 3b). In this case, a sinusoidal input was used to tune the controls.

When the tuning was completed, the old six-axis motion simulator had a new brain – this one much more flexible and precise than the old one, able to ensure that the show goes on to delight amusement park goers for years to come.

November/December 2010 | 19

IFPS Annual Meeting and 50th Anniversary The International Fluid Power Society (IFPS) met in Philadelphia, Pa., to conduct its 2010 Annual Meeting and to celebrate its 50th anniversary. This meeting marked the highest meeting attendance in IFPS history! Representatives from The International Fluid Power Society of Australia Inc. (IFPSA), National Fluid Power Association (NFPA), the Fluid Power Educational Foundation (FPEF), and the Fluid Power Journal were in attendance.

Special thanks should be made to the many dedicated IFPS professional members who attended the Board of Directors meeting, committee meetings, and strategic planning sessions. These individuals were instrumental in outlining a five-year plan for IFPS.

On the Horizon For 2011 • IFPS will offer a series of one-hour web learning sessions conducted by IFPS Accredited Instructors. Watch your e-mail and the IFPS Web site for updates.

• A new book titled Essential Practices Manual written by Raymond Hanley, CFPE/AI-Emeritus and a committee of subject matter experts is scheduled to be released in 2011.

Essential Practices Manual describes in-depth steps on how to build efficient fluid power solutions.

• IFPS will continue a review of all IFPS certifications. To date, the Industrial Hydraulic Technician (IHT), Industrial Hydraulic Mechanic (IHM), Pneumatic Technician (PT), and Pneumatic Mechanic (PM) certifications have been reviewed and updated and can be found by visiting www.ifps.org.

• IFPS has expanded dates for 2011 Live Distance Learning Programs for IFPS Hydraulic and Pneumatic Specialists Certifications.

• IFPS will continue development of the IFPS Mobile Electronic Controls (CFPMEC) and Industrial Electronic Controls (CFPIEC).

50th Anniversary Celebration Past Presidents Robert Kraft, CFPE, CFPS, and Clayton Fryer, CFPAI, CFPPM, CFPPT, CFPPS, acted as Masters of Ceremony for the IFPS anniversary dinner. Twelve speakers, nine of whom are IFPS past presidents, were introduced and shared their experiences with IFPS and the fluid power industry. Guests enjoyed great food, entertainment, and timeless camaraderie. The evening was whimsically closed with an “IFPS at Fifty Years” limerick written and delivered by Clayton Fryer. IFPS past presidents and executive directors in attendance at the anniversary celebration included Robert L. Wolff – President 1975-76 Robert Hanpeter – President 1980-81 Raymond Hanley – President 1986-87 John Groot – President 1998-99 Robert Sheaf – President 1999-2000 Lisa Reeve – President 2002 Art DesMarais – President 2004 Joe Lehmann – President 2005 Clayton Fryer – President 2006 Robert Kraft – President 2007 Liz Rehfus – President 2008 Robert Yund – President 2009 Rickey Rodeffer – President 2010 Jim Morgan – Executive Vice President and Secretary 1991-95 Paul Prass – Executive Director 1995 -2004 Donna Pollander – Executive Director, 2004 - present

From Left Front: Joe Lehmann, Raymond Hanley, Liz Rehfus, Robert Sheaf, Lisa Reeve, Robert Hanpeter From Left Back: Clayton Fryer, Rickey Rodeffer, John Groot, Robert L. Wolff, Robert Yund, Art DesMarais, Robert Kraft

20 | November/December 2010

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November/December 2010 | 21

Charlotte and Robert Hanpeter Marge and John Groot

From Left: Rickey Roddeffer, 2010 IFPS President with incoming President, Jon Jensen

The evening's Masters of Ceremony From Left: Clayton Fryer – President 2006 Robert Kraft – President 2007

Congratulations to IDP Association Management Company for a very well organized and successful 50th Anniversary Meeting.

Speaking for the 50-years-ago founders, I cannot thank all of you enough for bringing the Society to a much greater service to our Industry and its workers than we ever anticipated.

With heartfelt thanks...

Jim Morgan

From Left: Jim Morgan, Donna Pollander, Paul Prass

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Raymond F. Handley – President 1986-1987

Joe Lehmann President 2005

Lisa Reeve – 1st female President 2002

James I. Morgan – IFPS Executive Director 1991-95

Left: IFPS President, Rickey Rodeffer with Barry Catanach from International Fluid Power Society of Australia Inc.

Jimmy Simpson Education Committee Chair

Pat Maluso Finance Committee Chair

Wayne Farley Certification Committee Chair

Art DesMarais – President 2004

George Bufink Membership Committee Chair

Robert W. Hanpeter – President 1980-81

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Robert Sheaf – President 1999-2000

Robert L. Wolff – President 1975-76

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November/December 2010 | 23

Vacuum

Clampıng Fig. 1

By Daniel Pascoe, Vacuforce, Inc.

ne of the most common uses of vacuum cups and related vacuum products is material hold down or clamping. Often misunderstood, this article attempts to explain the basic selection process of components and the way in which they are employed.

In vacuum lifting, the performance is based upon the lifting capacity of the vacuum cups at a specific vacuum level. However in vacuum clamping applications, it is the holding force that is the determining factor of machine design success. Holding force is normally measured in Newtons (N), which is the Si unit of force measurement. The metric system, of course, offers simple conversions, and to help visualize Newton force, you can convert kg holding force to Newtons by multiplying the kg figure by 9.8 or using a “rule of thumb” by 10. Therefore, if you hang a 200kg weight off the bottom of a crane hook, the force being exerted is 1960N (200 x 9.8) or about 2000N if multiplied by 10.

The first question that needs to be asked of the vacuum user is what holding force they require when vacuum clamping. If the answer is 5000N, then visualize the part being “clamped” under vacuum, having a 500-kg weight laid upon it. It’s the same and no more complicated than that. Imagine that the user needs to clamp an aluminum billet on a CNC machining center while various holes are drilled into it. This machining process is straightforward enough that if the holes are of a small diameter and if the actual billet itself has significant mass, then only a small amount of additional clamping will be required. However, if the aluminum billet requires serious machining with pockets being milled out and the outside profile being machined to shape, then a more substantial hold down method will be required.

24 | November/December 2010

Many applications utilize the common toggle clamp, as shown in Fig. 1. However, the toggle clamp method is often a troublesome obstacle to the machinist if they have to negotiate around the clamps while machining an outside profile, taking clamps away while the cutter passes, etc. This is particularly irritating if there are many pieces to machine.

By utilizing vacuum pods, as shown in Fig. 2, the machine operator is able to mill the complete profile without interference. This is demonstrated in Fig. 3, which shows the same work piece before and after machining shape.

Toggle clamps give a very specific clamping force based on the leverage and distance between the pivot point and contact distance with the work piece. Toggle clamps also offer a very obvious clamping “feel” to the user, whereas with vacuum pods the clamping force is not as apparent. However a 6" diameter vacuum pod connected to a vacuum source such as compressed air venturi or electric pump can offer 1559N at 27"Hg of vacuum. Therefore, the five pods being used in the application shown in Fig. 3 offer 7794N of holding force. Significant, when you consider this is the same as placing a 1750-lb weight on top of

2 Fig. the work piece. Of course if you need a higher clamping force, use either more vacuum pods or ones with a larger surface area.

However, this is a vertical holding force. Serious consideration should be made to the type of vacuum seal or cup being used to resist side loading during machining. Fig. 4 shows a vacuum pod seal. This seal has zero deflection when under vacuum unlike the typical vacuum cup shown in Fig. 5, which will twist and flex under load. The seal shown in Fig. 4 has a particular surface that has small cusps protruding from the surface. These “grip” points offer significant resistance against side loads experienced during a machining process. A flat, smooth surface will offer very low friction and therefore low resistance against side loading.

Sometimes a machine bed with “submerged” vacuum cups is an effective solution as shown in Fig. 6, which uses the vacuum cup type shown in Fig. 5. The actual location face is now the machine

Fig. 3

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table, and the part is located against a secure datum.

With this method of vacuum clamping, the cup is simply pulling the work piece against the machine table face as the vacuum force compresses the vacuum cup. This is often used when machining larger work pieces such as steel sheet. Dimension X is the amount that the cup face protrudes above the machine table when there is no work piece in position. The vacuum cup should have a compression movement of more than this amount to allow location of the work piece against the machine table.

Vacuum generation is an important part of any vacuum system, but in vacuum clamping, often the wrong selection is made. Once the work piece is under vacuum and securely clamped in location, the vacuum source can be turned off to save energy. This, of course, is only practical if the vacuum seal is airtight and the part being held is not porous.

In applications where the system is airtight, however, switching off the vacuum pump or venturi is a tremendous power saving and can be achieved by the correct selection of a vacuum switch and control valve technology.

Significant production improvements can be achieved by utilizing the correct vacuum components in a material clamping application. However as in most industrial applications, there are many different methods and indeed preferences used to dictate the end solution, but the final result is often one of component availability and supplier expertise.

Daniel Pascoe is general manager of Vacuforce Inc, manufacturer and distributor of vacuum components and systems for industry in North America. Daniel can be reached via the Vacuforce Web site at www.vacuforce.com or directly at dpascoe@vacuforce.com

Fig. 4

Fig. 5

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.

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ProductReview

A Look At New & Innovative Products

Vacuum Generators

Air-Vac Engineering The MFL series of air-operating vacuum generators are available in four basic models: two sizes to generate high vacuum levels and high vacuum flow rates, and two sizes to generate medium vacuum levels and high vacuum flow rates with low air consumption. Mounting and muffler options are available to customize the installation. Features include a new design in a lightweight and compact package, mounting flexibility, and low purchase price/low operating cost. www.airvacpumps.com

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Vacuum Grippers

FIPA Inc. Vacuum grippers are designed in six different basic models from 70 x 70 x 160 x 160 millimeters and provide consistently strong gripping force for automatic handling of a wide range of materials. The vacuum required is provided by integrated high-performance ejectors using compressed air, following the Venturi principle. External vacuum generators are available as an option, e.g. regenerative blowers. Intelligent valve technology leaves vacuum openings that are not in use closed.

This means the vacuum remains constant at all times, compressed air consumption and therefore energy costs are reduced, and the durability of the vacuum mats is significantly increased. www.fipa.com

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Tank Level Gauges/Switches

Mid-West Instrument, Inc. Single and double switch options have been added to the company’s line of tank-level gauges designed for cryogenic/liquefied gas. Like the non-switch units, the single or double switch Model 116 indicating switches feature a dry bellows design with internal bi-directional relief valves with no liquid fill required to protect the unit from over-range. DP ranges from 0-80” H20 to 0-600” H20 (0-200 mbar to 1.5 bar). www.midwestinstrument.com

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Hydraulic Gear Pumps

Young Powertech Inc. Hydraulic gear pumps are factory engineered for tough applications. “D” ports are in compliance with threaded ports with O-ring seal in truncated housing SAE J1926/1 (ISO J1926-1). Industries for the gear pump motors include chemical process industries, refining and petrochemicals, adhesives and consumer products, pharmaceuticals and food products, power generation, oilfield and pipelines, and military and marine. www.yptius.com/hydraulicpumps.html

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Pneumatic

Theatrical Kits Fill Need for Low-Budget, High-Impact Special Effects

By Mickey Henry, Norcostco

F

rom the first tricks during the earliest stage performances to the amazing technological feats of Cirque D’ Soleil, fluid power has been a part of the entertainment industry. When money is of little object, the effects that can be created are amazing. When budgets are small and the artisans who are building the scenery are willing but not always able is where the challenge lies for many in the entertainment industry. Even with small budgets, stage effects using fluid power are possible.

My introduction to fluid power came while working toward my MFA in Technical Direction at the University of Arizona studying under Jon Jensen (CFPAI, CFPPS, CFPECS) at SMC Corporation.

This introduction to fluid power was not always in the classroom, but in typical theater fashion by trial-and-error engineering. Within the first weeks of graduate school, my work with pneumatics began.

During our production of “Sunday in the Park with George,” we used compact cylinders to open the bodice of a dress via remote control with a shopbuilt tank and modified R/C (radio-controlled) car www.ifps.org | www.fluidpowerjournal.com

1 3

1: University of Minnesota – Twin Cities The Crucible (Scenic Design and Photo By Lisa Kudas) 2: Northern Tool Part 143988 3: Hydramotion PPAC

2

November/December 2010 | 27

4

6

7

4: The Crucible (Photo by Carla Sandoval) Hydraulics Operator: Rachael Piersdorf 5: Minnesota Centennial Showboat “Is there a Doctor in the House” (Scenic Design and Photo By: Kit Mayer) 6: Bed frame in the midst of construction (Photo By: Mickey Henry) 7: Built-in Tank (Photo By: Mickey Henry)

5 parts to operate the valve. We also used pneumatics to open and close the top of the “Chromalume #7,” a small set piece that had smoke, flashing lights, and neon for effect. I was hooked. Beyond pneumatics, we possessed a small hydraulic system to power a variety of mobile hydraulic farm-use actuators. The system may have been small, but it had the power to open doors, lift platforms, and in one instance power a winch to lift the witch Hecate in our production of “Macbeth.” (Note: The flying of performers should be left to those who are specifically trained.)

Fast-forward a few years and many shows later. I was working as the technical director for the University of Minnesota. For our production of “The Crucible,” the designer and director desired to have three small platforms lift from the floor and represent the large furniture necessary in the show (Fig. 1). Typically this would have been cut from the show due to lack of resources. Through much 28 | November/December 2010

value engineering, I was able to accomplish the desired effect. I pieced together a small hydraulic system that consisted of three hydraulic scissor lifts purchased from Northern Tool (Fig. 2) and a Hydramotion PPAC hydraulic pump and tank combo (Fig. 3). I plumbed the lifts, bypassing the original foot pump and going directly into the cylinder.

The cylinders were single-acting, so I had to rely on gravity to retract the platforms into the stage. This was all controlled by the control board—literally a piece of plywood screwed into the wooden support structure of the set, serving as a mounting surface for the four control valves (Fig. 4). Three of the valves controlled the individual lifts, and the fourth held the pressure while the platforms were extended. To lift the platform, the pump was turned on and the fourth valve was opened, followed by the lift table valve. The fourth valve was then closed to hold pressure, and the pump was turned off to keep the hum of the motor down to a minimum. To

retract the platform, the fourth valve was opened, allowing the fluid to return back to tank. This system was very crude, but it worked and was very nearly under budget.

My next challenge was to build a bed for a production of “Is there a Doctor in the House” (Fig. 5). This bed needed to be moved around the set multiple times but not use the standard wagon brakes because of the very physical performances of the actors. Jon came to the rescue with a couple of older style 4" bore SMC CQ2 cylinders (Fig. 6). I then filled in the gaps with the newer versions of the cylinders. I created mounting plates to bolt casters onto the cylinders. The cylinders were then bolted into the steel frame of the platform. The cylinders were supplied with air by an 11-gallon air tank that was built into the structure and filled as part of the pre-show duties of the crew (Fig. 7). This large tank was used because of the original intention to have the bed move multiple times throughout the show.

The large cylinders were used because of the The use of fluid power in the theater does possibility of having several members of the cast not have to cost a fortune and for the most part on the bed while it was in operation (Fig. 8). it can’t. The resources are just not there. As you Theater technicians are notorious for borrowing can see, some interesting effects can be created technology from other fields and bending it to our for not great sums of money. Unfortunately, these will. When approaching a vendor, we often hear the solutions can be clunky and take time to work out words “You are going to do what with this?” After the bugs, but in the end they serve the purpose. It my experience creating the lift casters for the bed is to be hoped that the theatrical world continues and other small effects, I began to wonder why to borrow from the industrial world in a safe and pneumatics were not sold in kit form to theater effective manner. professionals. Once I left academia, I was able to For more information, visit www.norcostco.com. make this a reality. Thus, the Norcostco theatrical pneumatic kits were born. (Fig. 9) As SMC’s entertainment distributor, we are able to offer kits that 8: Bed in use 9 serve two areas: specials effects and lifting/braking.

(Photo by Everything from the connection to the compressor, Kit Mayer) the actuators, the valves, the tubing, and the fittings 9: Theatrical is supplied in the kit including the casters for the lift pneumatic kit mechanism. All that the user needs to supply is the compressed air. Norcostco will also size and build (Photo by Erik custom tanks for specific needs.

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November/December 2010 | 29

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High Torque, Low Speed Hydraulic Motors Western FluiDyne high torque, low speed hydraulic motors are a cost effective, form, fit and function interchange for the common brands of motors. Hundreds of displacements and model variations of the popular “H”, “S”, and “2000” series are in stock. Customer Service is available to provide technical information and assist in model code selection or interchange.

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Feroy valves are in use on directional drilling equipment, augers, winches, and mobile equipment attachments.

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ProductSpotlight | Conventional Valving, Repair & Reconditioning Check Valve Carriers

YOULI HYDRAULIC DIRECTIONAL CONTROL VALVES

Inserta® Check Valve Carriers provide a convenient and effective way to install an Inserta® ICS Slip-In check valve in a hydraulic system that uses SAE threaded ports. Alternatively, the carrier allows the check valve element to be positioned deep within a manifold. This carrier permits the check valve element to be oriented with free flow in either direction.

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Slip-in Check Valves Inserta® Products provides a wide range of check valves, in 1/8 inch to 3-inch sizes for flows up to 400 gpm, and low pressure drops. These slip-in check valves can be inserted in manifolds, subplates, flanges, or integrated systems. The patented full flow design results in less pressure drop than comparably sized cartridge valves and can be used in conjunction with straight thru, right angle, or tee branch machined cavities made without special form tooling. Flow control orifices are available.

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MODULAR STACK VALVES...D03...D05

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“A” FLANGE, 2DG SERIES DOUBLE PUMPS Now available from stock…Honor 2DG double pumps.

Honor Gear Pumps Corp. of Taiwan, with U.S. warehouse in Houston, Texas, is pleased to announce the immediate availability of their 2DG series, double pumps. The aluminum body pump, employs cast iron covers for best performance under extreme conditions, and comes standard with viton seals.

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FPDA | Motion & Control Network

AssociationNews

FPDA Announces Five Webinars Launching in October 2010 FPDA is pleased to announce that registration is open for five webinars designed by the Association Education Alliance, of which FPDA is an active member. The Association Education Alliance identifies, evaluates, and develops educational products and programs for use by member associations. Currently, there are more than 40 distribution-based associations that belong to AEA. The webinars will include: Tuesday, October 5 – Web Analytics: How to Measure the Success of Your Website – 1:00 Eastern Tuesday, November 16 – How to Reach New Customers with Online Public Relations – 1:00 Eastern Thursday, December 9th – 2011 Online Marketing Trends to Know Now – 3:00 Eastern Thursday, January 13th – Online Sales Success – Lead Generation and Buyer Behavior – 3:00 Eastern Thursday, February 10th – Mobile Marketing - Engaging Them at the Point of Need and Device of Choice – 3:00 Eastern

Web Analytics: How to Measure the Success of Your Web site

How will you know if your Web site is a success? Gone are the days when a marketer can rely on subjective measures, gut feel, or esoteric statistics like “hits.” To be successful with online marketing, you need to be able to accurately measure the bottom-line impact your Web site, search engine marketing, email marketing, and social media campaigns are having on your business. But how do you do it?

Spend 90 minutes with online marketing expert Bob DeStefano to learn how to measure your online marketing success leveraging Web Analytics. Whether you are an online marketing novice or an expert, you will learn actionable tips and proven strategies to • Define business-building success measures for your e-marketing campaigns • Discover your most profitable source of Web traffic • Pinpoint the flaws that are driving visitors away • Identify the most effective campaigns that turn visitors into customers • Measure your “offline” marketing success

How to Reach New Customers with Online Public Relations

The Web and social media have changed public relations forever. No longer is PR only about dealing with the press. Blogs and social media sites empower you to reach your customers and prospects directly, allowing you to establish credibility, build stronger bonds with customers, and generate new business opportunities. So, how do you effectively harness online PR to generate buzz that produces results?

Spend 90 minutes with online marketing expert Bob DeStefano to learn how to how to unlock your promotional potential with online PR leveraging blogging, content marketing, YouTube, LinkedIn, Facebook, Twitter, online newsrooms, and other social media. Whether you are an online marketing novice or an expert, you will learn actionable tips and proven strategies to • Generate sales leads with online press releases and articles • Develop a results-focused blogging strategy • Harness social media to generate business-building buzz • Dominate the Google results through content marketing • Monitor and manage your online reputation

www.ifps.org | www.fluidpowerjournal.com

2011 Online Marketing Trends to Know Now

Online users spent more than $250 billion last year. What percentage of your business came from that pool? How about in 2011? Are you realigning budget and resources to get higher percentage of each relationship’s mindshare and wallet share? How do you know? What is your view of customer lifecycle?

In 2011 and beyond, to stay relevant to online buyers and get higher return on your online marketing, you need to start with understanding of the state of world—the understanding that encompasses the shift in the buyer behavior, information overload, and holistic view of the customer. If customers no longer believe in what you say, how can you leverage broader sources of influence to get your message across?

FPDA invites you to join David Nour, author of Relationship Economics and Social Networking Best Practices Series, on Thursday, December 9, 2010 at 3 PM Eastern (Noon Pacific) to learn how to reorient your business toward a more holistic approach. In 60 minutes, he will start with addressing the key market, distribution, product, core competencies, and innovation assumptions you need to consider and redefine to better serve your online marketing goals and objectives in 2011 and beyond and continue with top online marketing best practices and trends for next year.

Future webinars include:

Thursday, January 13, 2011 | 3 PM Eastern (Noon Pacific) Online Sales Success - Lead Generation and Buyer Behavior Thursday, February 10, 2011| 3 PM Eastern (Noon Pacific) Mobile Marketing - Engaging Them at the Point of Need and Device of Choice To register for any of these webinars, please visit www.fpda.org.

November/December 2010 | 33

AssociationNews

NFPA | National Fluid Power Association

NFPA Fluid Power Challenge Online Instructions Now Available

T

he NFPA Fluid Power Challenge is a competition that challenges eighth grade students to solve an engineering problem using hydraulics and pneumatics. The students work in teams of four—two boys and two girls—to design and build a fluid power mechanism, and then compete against other teams in a timed competition.

Complete instructions for holding an NFPA Fluid Power Challenge are now available online.

Using the new instructions, any middle school, university, or fluid power company can now run a challenge event on their own. The instructions include a budget, timetable, and sample e-mails, along with forms that local organizers can use and customize for their individual events. The online instructions contain detailed information for challenge coordinators, facilitators, and judges, including ordering information for challenge kits, T-shirts, and trophies, as well as judging criteria and step-by-step procedures for the workshop day.

Teachers can also hold a fluid power challenge in their classrooms by using three new classroom exercise kits—a pneumatic lifter, rotational arm, and clamp—which demonstrate linear and rotational movements. These kits give teachers the tools they need to teach fluid power in the classroom and experiment with hydraulics and pneumatics before entering teams in a challenge event. Additional resources and supporting materials for the classroom exercise kits are also available.

The complete instructions can be found at the following link: http://www.nfpa.com/Education/Challenge_Instructions.asp.

The NFPA Fluid Power Challenge exposes middle school students to a learning environment where engineering and math are fun, and encourages

them to develop their teamwork and problem-solving skills. They are introduced to careers in the fluid power industry, and teachers receive support and resources for science and technology curriculum. The availability and easy-access of these instructions will greatly expand the number of challenges being held across the country.

Can’t Miss Events Happening During IFPE 2011

D

id you know that IFPE 2011 is filled with educational opportunities – from free presentations on the show floor to the new in-depth courses led by industry experts?

These education events will provide crucial information on new power transmission and motion control technologies to engineers and others involved in the design and manufacturing process. Can’t miss events include 52nd National Conference on Fluid Power – March 23-25, 2011, Las Vegas Convention Center The 52nd National Conference on Fluid Power is the #1 resource for information on the latest research for the design engineering community.

Wednesday and Thursday presentations will include keynote addresses from leading industry experts on pumps and hydraulic hybrids.

Innovations Theater – March 23-25, 2011 Las Vegas Convention Center IFPE 2011 attendees will benefit from free education sessions on the show floor. Experts in the field will present real-world solutions for current and future design applications.

Courses – March 21-22, 2011 Las Vegas Convention Center In depth courses focusing on lubrication, hydraulic hybrids, and noise, vibration, and harshness for fluid power systems include topics such as • Basic Lubrication • Hydraulic Fluids and Their Application • Noise in Hydraulic Fluid Power Systems • Design, Modeling, and Control of Hybrid Vehicles Upon completion of these courses, Continuing Education Units (CEUs) are available at no additional fee.

Course descriptions can be found at http://www.ifpe.com/Education/General/Courses/.

See you there!

34 | November/December 2010

Calendar of Events AG CONNECT 2011 Expo January 8 - 10, 2011 Georgia World Congress Center Atlanta, GA 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. Visit www.ifpe.com for more details.

Hannover Fair 2011 April 4 - 8, 2011 Motion, Drive & Automation (MDA), Hannover, Germany NFPA 2011 Industry and Economic Outlook Conference August 16 - 17, 2011 Renaissance Schaumburg Hotel Schaumburg, IL www.ifps.org | www.fluidpowerjournal.com

AssociationNews

IFPS | International Fluid Power Society

Certification Levels Available: CFPAI Certified Fluid Power Accredited Instructor

CFPPS Certified Fluid Power Pneumatic Specialist

CFPMHT Certified Fluid Power Mobile Hydraulic Technician

CFPAJPP Certified Fluid Power Authorized Job Performance Proctor

CFPECS Electronic Controls Specialist

CFPPT Certified Fluid Power Pneumatic Technician

CFPMEC – in development Mobile Electronic Controls

CFPAJPPCC Certified Fluid Power Authorized Job Performance Proctor Connector & Conductor CFPE Certified Fluid Power Engineer CFPS Certified Fluid Power Specialist (Must Obtain CFPHS, CFPPS)

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

CFPIEC – in development Industrial Electronic Controls CFPMT Certified Fluid Power Master Technician (Must Obtain CFPIHT, CFPMHT, & CFPPT)

CFPIHM Certified Fluid Power Industrial Hydraulic Mechanic

CFPMMH Certified Fluid Power Master of Mobile Hydraulics (Must Obtain CFPMHM, CFPMHT, & CFPCC) CFPMIP Certified Fluid Power Master of Industrial Pneumatics (Must Obtain CFPPM, CFPPT, & CFPCC)

CFPMHM Certified Fluid Power Mobile Hydraulic Mechanic

CFPIHT Certified Fluid Power Industrial Hydraulic Technician

CFPHS Certified Fluid Power Hydraulic Specialist

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

CFPCC Certified Fluid Power Connector & Conductor

CFPPM Certified Fluid Power Pneumatic Mechanic

IFPS Announces 2011 Board of Directors Jon Jensen, CFPPS, CFPECS, CFPAI, SMC Corporation of America, was elected as the 51st president of the International Fluid Power Society during its recent Annual Meeting in Philadelphia, Pa. Mr. Jensen will take office in January 2011.

The following Officers were also confirmed at the IFPS 2010 Annual Meeting: • First Vice President Pat Maluso, CFPMHM, CFPS, CFPAI, Western Hydrostatics, Inc. • Immediate Past President Rickey L. Rodeffer, CFPMT, CFPS, CFPMIH, CFPAI, The Boeing Company • Treasurer Tom Blansett, CFPS, CFPAI, Eaton Corporation

• Vice President Certification Wayne Farley, CFPAI, CFPMMH, American Electric Power • Vice President Marketing & Public Relations Mark Perry, CFPHS, Fitzsimmons Hydraulics • Vice President Education Jimmy Simpson, CFPMM, CFPS, CFPAI, Nusim & Associates • Vice President Membership/ Chapter Support George Bufink, CFPAI, CFPMMH, American Electric Power - Retired The following Directors-at-Large were also confirmed: (Term expiring 2011) Justin Sergeant, CFPS, Open Loop Energy, Inc. Bismark (Bill) Castaneda, CFPHS, Automation Tech, Inc.

Jeremiah Johnson, CFPHS, Caterpillar, Inc. Samuel Skelton, CFPPS, CFPAI, SMC Corporation of America (Term expiring 2012) 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 (Term expiring 2013) Mike Anderson, CFPS, Motion Industries Bill Jordan, CFPMHM, CFPAI, Altec Industries Rance Herren, CFPS, National Oilwell Varco

IFPS Newly Certified David Behan, MIH, IHT The Boeing Company

Bruce Garlick, AJPP Eaton Corporation

Alan Bergstrom, Sr., AI, AJPP IUOE Local #478

Robert Guillemette, PS Bimba Manufacturing Company

Thomas Blansett, AI Eaton Corporation Mike Browner, III, PS Bimba Manufacturing Company

IFPS Calendar

Christopher Jeffery, AI, AJPPCC Eaton Corporation

Robert McGray, AI SMC Corporation of America

Nathan Katzenmeier, MHM Altec Industries, Inc.

Mike Metcalf, AJPPCC Pirtek USA

Curtis Guzek, MIH, MT, IHT The Boeing Company

Gary Klingshirn, AI, AJPPCC Eaton Corporation

Kenneth Meyers, MHT Altec Industries, Inc.

Benjamin Haake, MHM Dueco, Inc.

Edward Koranda, PS Bimba Manufacturing Company

Richard Richter, MHM Wisconsin Public Service

Wendell Canfield, MHM Wisconsin Public Service

Daniel Helgerson, AI, AJPP Cascade Steel Rolling Mills, Inc.

Peder Ellefson, MHM Xcel Energy

James Janzen, MHM Altec Industries, Inc.

www.ifps.org | www.fluidpowerjournal.com

Matthew McCue, PS Bimba Manufacturing Company

Dan Helgerson, CFPS, CFPPMT, CFPAI, Cascade Steel Rolling Mills, Inc. Honorary Directors-at-Large Robert Firth Raymond Hanley, CFPE/AI-Emeritus John Groot, CFPPS Robert Sheaf, CFPAI, CFPE, CFPMM, CFPMT, CFPMIP, CFPMMH, CFPMIH, CFPECS The following have fulfilled their tenure on the IFPS Board: Dennis Crouch, CFPCC, CFPHS, CFPIHT, CFPAI, General Motors (retired) Leo C. Henry, CFPMHM, CFPCC, CFPAI, Altec Industries, Inc. Robert Yund, CFPS, CFPIHT, CFPCC, CFPAI Hennepin Technical College

Aleksandr Shmushkin, AI SMC Corporation of America

IFPS 2011 Spring Meeting February 23–26, 2011 Orlando, FL IFPE March 22–26, 2011 Las Vegas, NV IFPS 2011 Annual Meeting September 14-17, 2011 Chicago, IL

Kevin Ziert, MHM Wisconsin Public Service November/December 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 e-mailed instructions. Testing dates for any locations listed below are as follows: November 2010 Tuesday, 11/2 Thursday, 11/18

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

January 2011 Tuesday, 1/4 Thursday, 1/20

February 2011 Tuesday, 2/1 Thursday, 2/17

March 2011 Tuesday, 3/1 Thursday, 3/17

April 2011 Tuesday, 4/5 Thursday, 4/21

May 2011 Tuesday, 5/3 Thursday, 5/19

June 2011 Tuesday, 6/7 Thursday, 6/16

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

Georgia Southern University Statesboro, GA

Northern Illinois University De Kalb, IL

Irvine Valley College Irvine, CA

FLORIDA Brevard Community College Cocoa, FL

Georgia State University Atlanta, GA

Parkland College Champaign, IL

University of Georgia Athens, GA

Richland Community College Decatur, IL

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 Florida Southern College Lakeland, FL Hillsborough Community College Plant City, FL Indian River State College Fort Pierce, FL Miami Dade College Miami, FL Open Campus Florida Community College at Jacksonville, FL

Glendale Community College Glendale, AZ

COLORADO Community College of Aurora Aurora, CO

Mesa Community College Mesa, AZ

Community College of Denver Denver, CO

Santa Fe Community College Gainesville, FL

Northern Arizona University Flagstaff, AZ

Fort Lewis College Durango, CO

University of Florida Gainesville, FL

Paradise Valley Community College Phoenix, AZ

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

University of South Florida Tampa, FL

Pima Community College Tucson, AZ

Pikes Peak Community College Colorado Springs, CO

Valencia Community College Orlando, FL

Rio Salado College Tempe, AZ

Pueblo Community College Pueblo, CO

CALIFORNIA Allan Hancock College Santa Maria, CA

University of Colorado at Boulder Boulder, CO

GEORGIA Albany State University Albany, GA

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 | November/December 2010

Polk State College Winter Haven, 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

IOWA Hawkeye Community College Waterloo, IA

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

University of Iowa Iowa City, IA

Ivy Tech Community College/ Columbus | Columbus, IN

Wartburg College Waverly, IA Western Iowa Community College Sioux City, IA

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

IDAHO Boise State University Boise, ID

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

www.ifps.org | www.fluidpowerjournal.com

KANSAS Johnson County Community College Overland Park, KS

Southwestern Michigan College Dowagiac, MI

Gloucester County College Sewell, NJ

University of Oregon Eugene, OR

Texas A&M International University Laredo, TX

Washtenaw Community College Ann Arbor, MI

Mercer County Community College West Windsor, NJ

Texas A&M University College Station, TX

University of Kansas Lawrence, KS

MINNESOTA Minnesota State University, Mankato Mankato, MN

Raritan Valley Community College Somerville, NJ

PENNSYLVANIA Bucks County Community College Newtown, PA

Wichita State University Wichita, KS

University of Minnesota - Twin Cities Minneapolis, MN

NEW MEXICO Eastern New Mexico University Portales, NM

KENTUCKY University of Louisville Louisville, KY

University of Minnesota Morris, MN

San Juan College Farmington, NM

Harrisburg Area Community College York Campus | York, PA

MISSOURI Avila University Kansas City, MO

NEVADA College of Southern Nevada Charleston Campus Las Vegas, NV

Harrisburg Area Community CollegeLancaster Campus | Lancaster, PA

Kansas State University Manhattan, KS

Western Kentucky University Bowling Green, KY LOUISIANA Bossier Parish Community College Bossier City, LA University of Louisiana at Monroe Monroe, LA Nicholls State University, Thibodaux, LA University of New Orleans New Orleans, LA MARYLAND Anne Arundel Community College Arnold, MD Carroll Community College Westminster, MD Chesapeake College Wye Mills, MD College of Southern Maryland La Plata, MD Frederick Community College Frederick, MD Harford Community College Bel Air, MD Hagerstown Community College Hagerstown, MD

Metropolitan Community College-Penn Valley | Kansas City, MO Missouri Western State University St.Joseph, MO

College of Southern Nevada Cheyenne Campus North Las Vegas, NV

Midlands Technical College Columbia, SC

Victoria College Victoria, TX

Piedmont Technical College Greenwood, SC

UTAH Brigham Young University Provo, UT

Three Rivers Community College Poplar Bluff, MO University of Central Missouri Warrensburg, MO Webster University St. Louis, MO MISSISSIPPI Holmes Community College Goodman Campus | Goodman, MS Mississippi State University Mississippi State, MS University of Mississippi University, MS

Rochester Institute of Technology Rochester, NY OHIO Central Ohio Tech College/OSUNewark | Newark, OH Columbus State Community College Columbus, OH Franklin University Columbus, OH Rhodes State College Lima, OH The Ohio State University Columbus, OH

Fayetteville State University Fayetteville, NC

Oklahoma State University Stillwater, OK

MICHIGAN Baker College Online Flint, MI

Guilford Technical Community College Jamestown, NC

Oklahoma State University-Tulsa Tulsa, OK

Schoolcraft College Livonia, MI

University of Texas El Paso El Paso, TX

NEW YORK Brooklyn College - CUNY Brooklyn, NY

University of Massachusetts Boston, MA

Michigan State University East Lansing, MI

Horry-Georgetown Technical College Conway, SC

State Fair Community College Sedalia, MO

OKLAHOMA Northern Oklahoma College Tonkawa, OK

Macomb Community College Warren, MI

University of Texas at Arlington Arlington, TX

Weatherford College Weatherford, TX

NORTH CAROLINA East Carolina University Greenville, NC

Lansing Community College Lansing, MI

University of Texas - Brownsville Brownsville, TX

Orangeburg Calhoun Technical College Orangeburg, SC

MASSACHUSETTS North Shore Community College Danvers, MA

Lake Superior State University Sault Ste. Marie, MI

University of Houston Houston, TX

College of Southern Nevada Henderson Campus, NV

The University of Montana Missoula, MT

Kalamazoo Valley Community College Kalamazoo, MI

Tyler Jr. College Tyler, TX

St. Charles Community College Cottleville, MO

University of Maryland College Park, MD

Henry Ford Community College Dearborn, MI

SOUTH CAROLINA Coastal Carolina University Conway, SC

Texas Tech University Lubbock, TX

Southeast Missouri State University Cape Girardeau, MO

MONTANA Montana State University Bozeman, MT

Ferris State University Big Rapids, MI

Harrisburg Area Community College Harrisburg, PA

Texas A&M University-Commerce Commerce, TX

College of Southern Nevada Green Valley Campus Henderson, NV

Howard Community College Columbia, MD

Delta College University Center, MI

HACC Gettysburg Campus Gettysburg, PA

Mount Olive College Mount Olive, NC North Carolina Central University Durham, NC North Dakota State University Fargo, NC The University of North Carolina Wilmington, NC NORTH DAKOTA Bismarck State College Bismarck, ND NEBRASKA Bellevue University Bellevue, NE Southeast Community College Lincoln, NE NEW JERSEY Brookdale Community College Lincroft, NJ

www.ifps.org | www.fluidpowerjournal.com

The University of Toledo Toledo, OH University of Akron Akron, OH

University of Central Oklahoma Edmond, OK University of Oklahoma Norman, OK OREGON Central Oregon Community College Bend, OR Clackamas Community College Oregon City, OR Mt. Hood Community College Gresham, OR Portland Community College Rock Creek Portland, OR Portland State University Portland, OR RCC-SOU Higher Education Center Medford, OR Southwestern Oregon Community College | Coos Bay, OR

Spartanburg Community College Spartanburg, SC Technical College of the Lowcountry Beaufort, SC Trident Technical College Charleston, SC

Davis Applied Technology College Kaysville, UT Salt Lake Community College Salt Lake City, UT Utah Valley State College Orem, UT

York Technical College Rock Hill, SC

Weber State University Ogden, UT

TENNESSEE East Tennessee State University Johnson City, TN

VIRGINIA Old Dominion University Norfolk, VA

Middle Tennessee State University Murfreesboro, TN

WASHINGTON Central Washington University Ellensburg, WA

Southern Adventist University Collegedale, TN Tennessee State University Nashville, TN The University of Memphis Memphis, TN Walters State Community College Morristown, TN TEXAS Abilene Christian University Abilene, TX Austin Community College Austin, TX Collin Community College - Spring Creek Campus | Plano, TX Eastfield College Mesquite, TX El Paso Community College El Paso, TX Grayson County College Denison, TX Lamar Institute of Technology Beaumont, TX Lamar University Beaumont, TX

Olympic College Bremerton, WA Western Washington University Bellingham, WA WISCONSIN Lakeshore Technical College Cleveland, WI Marian University of Fond du Lac Fond du Lac, WI University of Wisconsin Oshkosh Oshkosh, WI University of Wisconsin-Milwaukee Milwaukee, WI UW-Green Bay Green Bay, WI WYOMING University of Wyoming Laramie, WY CANADA Lethbridge College Lethbridge, AB Canada Saskatchewan Institute of Applied Science and Technology Saskatchewan, Canada Thompson Rivers University Kamloops, BC Canada

Midwestern State University Wichita Falls, TX Sam Houston State University Huntsville, TX Southern Methodist University Dallas, TX

November/December 2010 | 37

ProfessionalDevelopment

By Don Farrell

Drive the Greatest Revenue Results: Use the 3 Rules in Loyalty Sales Calling

L

oyalty, vs. any other adjective or adverb you can come up with, is the best way to approach selling your potential clients for immediate and long-term results.

The first example of loyalty in a known commodity is selling gas at a gas station. Can you use this example in all selling situations?

You own a gas station, and you know that the net profit margin is very slim, so you can’t afford to lower prices or offer freebies as an incentive to picking up and retaining new customers. So how can you create a more loyal customer? Most gas station customers are probably looking at price and location as the two greatest features. If your price is comparable to the next guy and you are on their way to and from work, then people will more than likely call your gas station theirs. However, this is not much of a loyalty-driving proposition. What if the lighting at your gas station is weak, the window cleaning solution habitually dry, the pumps dirty, or the receipt doesn’t come out like it should? Enough reason(s) to chase customers to the next station? Probably. What if you, as the owner or manager, not only had these lighting and other operational fundamentals in place, but in addition you also made it a habit of walking the pump area, picking up trash, and talking to your customers. What would happen if you said, “Hi, my name is _____ and I own/ manage this station. I f you need anything I will be out here or just inside. Thanks for using us for your gas needs.” When is the last time you received this kind of a free benefit at a gas station? Never or very rarely.

Customers would probably be blown away because they wouldn’t expect it.

This is the first step in driving loyalty– exceeding expectations.

Let’s try another example, one that has repeated hundreds of times. You are a 25-year-old woman who is planning her wedding, something you’ve probably been thinking about for the past 20 years.

Like all women and men, you want this day to be perfect, one of the very best of your entire life. You are getting ready to make the most important phone calls that will determine how your special day will go and the area that more things can go wrong or right.

38 | November/December 2010

That’s right, we are talking about the reception facility. How many places will the bride-to-be call to set up an appointment to meet with the catering staff to then determine which facility wins her trust? Three, four, five? Regardless of how many, she will more than likely have a conversation with an experienced wedding planner who focuses on three very selfish things: rates, dates, and space. Those will be the three things the catering veteran will want to know in determining whether they even wants this bride’s business. This catering professional fields many calls in a day, in a week, in a month asking the same kinds of things, so she has learned to streamline the calls to save herself time. She may be a veteran wedding planner, but she has learned how not to have a customer centric approach to selling or driving loyalty with that soon-to-be bride.

So rule # 2 in driving loyalty with your potential and existing customers/clients is to make an emotional connection.

Why should you be concerned with loyalty? If you go into your wallet, you will see that you have a fair amount of frequency or loyalty program cards, some from competing brands of each other. The truth is, as consumers, people are looking for more than satisfaction. They want personal perks, surprises, and value-added kinds of goods and services. It sometimes makes up for the bad service they can get, but how much more loyalty would you be driving if the fundamentals are in place and on top of the stuff customers were supposed to get, they got a surprise bonus? Emotional connections with managers who go out of their way to show care and concern and surprises in the form of getting a delivery that exceeds my expectations as a consumer.

As business owners and operators, you already know that it is expensive to find new customers and even more expensive to fix things they are dissatisfied with. Your mission should not be to make customers satisfied but to go beyond satisfaction and straight

to a commitment of loyalty the very second the experience begins. Go back to the catering director who fielded the wedding reception request. Instead of focusing on the catering hall’s selfish rates, dates, and space needs, she instead made the bride feel incredibly special by beginning the conversation with an incredibly passionate tone: “…well, Charlotte, let me just say congratulations to you and David on several levels. First for your upcoming wedding and secondly, for choosing to consider us for your reception needs.

My staff and me are absolutely committed in every way possible to making this wedding day one of the very best days of your life…”

Caring more, doing more, and communicating that you care better than any one of your competitors is what business leaders need to be doing.

Making the emotional connection and keeping the customer/client focus before our own selfish gains also solidifies and earns that loyalty.

So rule # 3 is putting customer needs before your own needs.

Delivering the basics creates satisfaction but does not drive loyalty. Satisfaction is what consumers are supposed to get. Loyalty comes from the added bonuses talked about here. Delivering more than customers expect is the name of the game each and every day. You can’t wow them just once, but each and every time you touch them and they touch you, loyalty needs to be driven home. When you do this, incredible things happen. People buy stuff from you and they come back for more!

About the author: Don Farrell is the author of “Ethical Theft…

How to Steal Business.” He is a speaker who conducts training workshops and consults select clients on how to create unique sales and service cultures. For more information, visit www.FreshRevenues.com or call 731-514-1589. www.ifps.org | www.fluidpowerjournal.com

CalendarofEvents

November/December 2010

DECEMBER

8-10 2-day Pneumatic Troubleshooting with Schematics Cincinnati, OH CFC-Solar, Inc. Tel: 513-874-3225 www.cfc-solar.com

6-10 Wind Turbine Fundamental Hydraulics Maumee, OH Eaton Hydraulics Group Tel: 800-413-8809 http://web.fluidpower.eaton.com

6-7 Introduction to Pneumatics Cincinnati, OH CFC-Solar, Inc. Tel: 513-874-3225 www.cfc-solar.com 6-9 Introduction to Hydraulic Systems Modeling and Simulation Milwaukee, WI MSOE Tel: 414-277-7269 www.msoe.edu 6-10 Electromechanical Fundamentals Rohnert Park, CA Parker Hannifin Tel: 216-896-2577 www.parker.com/training

Serious About Surplus!

6-10 3- or 5-Day Electronic Controls including Safety and Test Equipment Cincinnati, OH CFC-Solar, Inc. Tel: 513-874-3225 www.cfc-solar.com

13-15 3-day Hydrostatic Closed Loop Systems for Engineers Cincinnati, OH CFC-Solar, Inc. Tel: 513-874-3225 www.cfc-solar.com

7-9 IFPS Hydraulic Specialist Certification Review Eden Prairie, MN Eaton Hydraulics Group Tel: 800-413-8809 http://web.fluidpower.eaton.com

13-17 3- or 5-day Basic Pneumatics Cincinnati, OH CFC-Solar, Inc. Tel: 513-874-3225 www.cfc-solar.com

7-10 Hydraulic Maintenance Technology Buena Park, CA Parker Hannifin Tel: 216-896-2577 www.parker.com/training

13-17 Mobile Hydraulics 400 Eden Prairie, MN Eaton Hydraulics Group Tel: 800-413-8809 http://web.fluidpower.eaton.com

Classifieds

Seriously! We’ll Make You The Best Offer on:

• Hydraulic cylinders, valves, motors & more • PTO shafts, universal joints & gear boxes • Bearings of all kinds, roller chain, sprockets, tires, wheel assemblies, seats, engines, most anything related to lawn & garden and off road Larry Leggett 1-800-800-1810 Ext.3202 Fax: 1-800-800-1811 email: LLeggett@baileynet.com

CIL-MM14 FPJ

1/27/10

9:58 AM

Page 1

Bailey Surplus Serious About Surplus

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NEW AIR JETS Unique design Multiple nozzles & orifices Pressure up to 200 psig #10-32 & 1/8-27 NPT In stock for immediate delivery

10 www.ifps.org | www.fluidpowerjournal.com

877-245-6247

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

November/December 2010 | 39

Classifieds

November/December 2010

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Sign up for this paperless format at www.fluidpowerjournal.com

FPJ5.1.08:Layout 1

5/8/08

3:34 PM

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 Contact Our Buyers Phone 402-474-4055 Fax 402-474-5198 email buyer@surpluscenter.com www.surpluscenter.com Buying and Selling Surplus Since 1933

Advertiser Index Company Page Alloys and Components..................................... 22 Ametek Automation and Process Technologies... 6 Ametek Automation and Process Technologies... 9 Ametek Automation and Process Technologies. 30 Attica Hydraulic Exchange Corp.PPL................... 9 Attica Hydraulic Exchange Corp.PPL................ CIII Clippard Instrument Lab Inc..............................CIV Clippard Instrument Lab Inc................................. 9 DELTA Computer Systems Inc........................... 17 Feroy Company Inc........................................... 25 Feroy Company Inc........................................... 31 Flange Lock....................................................... 15 Flaretite............................................................. 25 Flaretite............................................................. 30 Fluid Power Training Institute............................... 8 Harvard Corporation.......................................... 16 Harvard Corporation.......................................... 31 Hercules Sealing Products................................... 9 Honor Pumps U.S.A.......................................... 32 Honor Pumps U.S.A.......................................... 29 Hydraulics International Inc.................................. 9 Hydraulics International Inc................................ 11 IFPE.................................................................... 3 Inserta............................................................... 26 Inserta............................................................... 32 Inserta............................................................... 32 La-Man Corp..................................................... 10 Lehigh Fluid Power............................................ 31 Lightning Hybrids............................................... 17 Pag Manufacturing Products............................ 10 Main Main Manufacturing Products............................ 30 Marzocchi Pumps.............................................. 10 Peninsular Cylinder Co. Inc................................ 30 Peninsular Cylinder Co. Inc................................ 10 Power Valve......................................................... 8 Power Valve....................................................... 32 Sunfab North America....................................... 16 TR Engineering Inc........................................... CII TR Engineering Inc........................................... 11 Ultra Clean........................................................ 30 Webster Instruments......................................... 29 Western Fluidyne............................................... 31 Yates Industries Inc.............................................. 1 Yates Industries Inc............................................ 11 Yates Industries Inc............................................ 31 Youli.................................................................. 22 Youli.................................................................. 32 Young Powertech.............................................. 23 Young Powertech.............................................. 11

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