Fluid Power Journal November 2020 by Innovative Designs & Publishing, Inc.

NOVEMBER 2020

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IN THIS ISSUE

NOVEMBER 2020

VOLUME 27 • ISSUE 10

Features 9 Test Your Skills Electric Flow Control Devices 12

Cover Story Eliminating Water Contamination in Air Systems It’s not the heat, it’s the humidity.

22 Hydraulic Cylinder Cushions Fight Mechanical Shock Sudden stops add stress to a machine and its cylinders. 28 Optimizing Efficiency to Meet Emissions Regulations Designers cope with demands for lower noise levels and fuel consumption. 30 Stepper Technology Boosts Firefighting Efficiency With lives often on the line, stepper valves fine-tune the water-and- foam mix that chokes the flames.

Departments

28 Publisher’s Note: The information provided in this publication is for informational purposes only. While all efforts have been taken to ensure the technical accuracy of the material enclosed, Fluid Power Journal is not responsible for the availability, accuracy, currency, or reliability of any information, statement, opinion, or advice contained in a third party’s material. Fluid Power Journal will not be liable for any loss or damage caused by reliance on information obtained in this publication.

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Keeping Customers Engaged in a Changing World By Hakan Erdamar, Group President, Discrete and Industrial, Emerson Automation Solutions

NO ONE COULD have foreseen the enormous personal, financial, and social damage of the COVID-19 pandemic. Businesses and livelihoods have been disrupted around the globe, presenting challenges beyond those brought by new technologies, climate and demographic change, and government regulations. But with those challenges come opportunities to strengthen commerce and our relationships and communities. Customers are counting on us to deliver. We need to meet their evolving needs and expectations. Our focus on our customers has increased efforts to ensure our customers are safe, well-informed, and continuously educated. Here are a few ways we’ve adapted to their needs. As an essential business that supports critical infrastructure, we have numerous strategies in place to safeguard our employees’ health and ensure that customer interaction is safe. We have rethought key aspects of how business is conducted. For example, we successfully moved our entire sales support staff to a remote model during the height of the pandemic and leveraged the technology to train and expand capabilities. And we actively engage with our customers to assess when we can safely resume faceto-face collaboration. In some cases, personal interaction is still preferable to aid the application of new technologies, support a solution design, or help with operational and service issues. One way to do so is with our Mobile Road Show, which will allow us to meet with our European customers over the next year. We now have a virtual means of sharing the same experience with customers who cannot allow third parties into their facilities because of social-distancing practices. We’ve pivoted to meet the evolving needs of our customers by adjusting and prioritizing production to help ease supply-chain burdens caused by demand ramp-up in key categories. Our facilities are operating with minimal downtime, and we’ve implemented extensive safety protocols. The channels through which we communicate with our global teams and customers are changing. We have reimagined how we use digital tools for trade shows and industry events that were shuttered. Our priority remains being available to collaborate with our customers and partners on the operational, safety, and efficiency challenges they face. And that’s why we’ve prioritized updates to our website, developed interactive content, and made investments to keep our sales teams wellequipped and our engineers accessible. The COVID-19 pandemic has afforded us an opportunity to leverage our digital tools and communications capabilities to reach out to our field sales, service, and business development resources and provide training and development opportunities. (Continued on page 5)

NOVEMBER 2020

Founders: Paul and Lisa Prass Associate Publisher: Bob McKinney Editor: Michael Degan Technical Editor: Dan Helgerson, CFPAI/AJPP, CFPS, CFPECS, CFPSD, CFPMT, CFPCC - CFPSOS LLC Art Director: Quynh Fisher Eastern Region Acct Executive: Norma Abrunzo Director of Creative Services: Erica Montes Accounting: Donna Bachman, Sarah Varano Circulation Manager: Andrea Karges INTERNATIONAL FLUID POWER SOCIETY 1930 East Marlton Pike, Suite A-2, Cherry Hill, NJ 08003-2141 Tel: 856-489-8983 • Fax: 856-424-9248 Email: AskUs@ifps.org • Web: www.ifps.org 2020 BOARD OF DIRECTORS President: Jeff Kenney, CFPMHM, CFPIHM, CFPMHT - Dover Hydraulics South Immediate Past President: Timothy White, CFPAI/AJPP, CFPS, CFPECS, CFPMIH, CFPMMH, CFPMIP, CFPMT, CFPMM - The Boeing Company First Vice President: Rocky Phoenix, CFPMMH - Open Loop Energy, Inc. Treasurer: Jeff Hodges, CFPAI/AJPP, CFPMHM - Altec Industries, Inc. Vice President Certification: Denis Poirier, Jr., CFPAI/AJPP, CFPHS, CFPIHM, CFPCC - Eaton Corporation Vice President Marketing: Scott Sardina, PE, CFPAI, CFPHS Waterclock Engineering Vice President Education: Kenneth Dulinski, CFPAI/AJPP, CFPECS, CFPHS, CFPMIH, CFMMH, CFPMT - Macomb Community College Vice President Membership: John Bibaeff, PE, CFPAI, CFPE, CFPS DIRECTORS-AT-LARGE Chauntelle Baughman, CFPHS - OneHydraulics, Inc. Stephen Blazer, CFPE, CFPS, CFPMHM, CFPIHT, CFPMHT Altec Industries, Inc. Randy Bobbitt, CFPAI, CFPHS - Danfoss Power Solutions Cary Boozer, PE, CFPE - Motion Industries, Inc. Lisa DeBenedetto, CFPS - GS Global Resources Daniel Fernandes, CFPECS, CFPS - Sun Hydraulics Brandon Gustafson, PE, CFPE, CFPS, CFPIHT, CFPMHM - Graco, Inc. Garrett Hoisington, CFPAI/AJPP, CFPS, CFPMHM Open Loop Energy Brian Kenoyer, CFPHS - Five Landis Corp. James O’Halek, CFPAI/AJPP, CFPMIP, CMPMM The Boeing Company Mohaned Shahin, CFPS - Parker Hannifin Randy Smith, CFPHS - Northrop Grumman Corp. HONORARY DIRECTORS-AT-LARGE AND EX-OFFICIO Ex-Officio: Donna Pollander, ACA, Executive Director Elizabeth Rehfus, CFPE, CFPS Paul Prass, Fluid Power Journal Robert Sheaf, CFPAI/AJPP, CFC Industrial Training

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Fluid Power Journal (ISSN# 1073-7898) is the official publication of the International Fluid Power Society published monthly with four supplemental issues, including a Systems Integrator Directory, Off-Highway Suppliers Directory, Tech Directory, and Manufacturers Directory, by Innovative Designs & Publishing, Inc., 3245 Freemansburg Avenue, Palmer, PA 18045-7118. All Rights Reserved. Reproduction in whole or in part of any material in this publication is acceptable with credit. Publishers assume no liability for any information published. We reserve the right to accept or reject all advertising material and will not guarantee the return or safety of unsolicited art, photographs or manuscripts.

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(Continued from page 4) Over the last several months, we’ve executed more than 7,000 training sessions globally covering new products, solution approaches to help customers, and skill-enhancing training topics. In many cases, our customers are working with reduced staff or staff that is being tasked with responsibilities to which they are not accustomed. As part of our commitment to helping our customers through the pandemic, Emerson is making many of the same online learning resources used by our teams accessible for free through the remainder of 2020. With more than 100 self-paced learning modules, this no-cost online training will be of particular value to contractors, wholesalers, end users, facility maintenance teams, engineers, and original equipment manufacturers who want to stay up to speed on new technologies. We believe encouraging our customers to continue their professional development during the pandemic and over the course of the economic recovery helps them adjust to their changing circumstances and supports their long-term success. We are also offering specialized Industrial Internet of Things (IIoT) introductory sessions, providing customers the opportunity to learn how to build successful IIoT strategies while leveraging Emerson’s Digital Transformation toolkits and architecture. This approach makes it easy for customers to start small, turning actionable insights into operational improvements, and calculating a return on their IIoT investment. It can also make it easier to strategically scale across multiple production lines, a single facility, or a broader operational model. When a crisis hits, companies need to react to new challenges without losing their vision. They need to respond quickly but also plan for the long term. The world is challenged right now – in our businesses, our communities, and even our families. There are no easy answers. But with disruption comes opportunity. New skills and capabilities develop. New opportunities to serve customers at a deeper level present themselves. And being accessible and willing to help takes on a greater meaning. This is a chance to reconnect with our customers, yes, but also with our employees and our families. Now is the time to strengthen our communities, build an inclusive, diverse workforce, and challenge ourselves to change. By approaching the pandemic as an opportunity to establish deeper connections, rethink old paradigms, and create new value, we can move forward with confidence to fully support our customers’ businesses while enriching the global community. 

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NOVEMBER 2020

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

The following is an opinion article written by Dane Spivak of Davasol Incorporated, an industrial brand management firm with many clients, including Vacuforce LLC, which partnered in the writing of this article. Contact Dane Spivak by email at dspivak@davasol.com.

Vacuum gripping systems are used in the wood industry for pick & place applications as well as vacuum hold down for machining and processing. Wooden parts come in many shapes and sizes, and, more relevant to this article, differ in surface characteristics where vacuum cups need to seal. Gripping systems start from the pump producing vacuum and end at the cups sealing against the product surface. Components in between are used to tie together a fully functioning system. Many applications share the same basic parts but require different design techniques to produce a reliable output. The following article touches on these facets.

Exhaust Port Gripper Connection Pump Connection

VACUUM SOURCES A variety of vacuum pump types can be used for wood gripping. However, most popular methods include venturi generators, rotary vane pumps, and regenerative blowers. Venturis use compressed air to generate vacuum, which can be a good choice depending on the application and the userâ&#x20AC;&#x2122;s accessibility to compressed air. Despite their small size, venturis can reach fairly high vacuum levels, up to 27 inHg (90% vacuum). Vane pumps are also known for their comparatively higher vacuum levels for vacuum gripping applications as they can reach over 29 inHg (96% vacuum). Vane pumps are powered by electric motors unlike the venturi. The electrically driven regenerative blowers are known for their high flow capacities and are more often used for larger systems or applications with significant leakage. Although their maximum vacuum levels can vary from 0-21 inHg (70% vacuum), their energy is put into the vacuum flow, which can prove to be beneficial to the system needs. Figure 1 gives examples of each unit. Their appropriate uses will be discussed in more detail later in this article.

Figure 1: From left, venturi, vane pump, and regenerative blower (not to scale).

FILTERS Continuing through the vacuum system, vacuum filters would be most appropriate to discuss next. Vacuum filters are used to protect pumps or venturis and are often close coupled to the vacuum unit itself. The filter protects the pump from unwanted dust, debris, oil, water, and other unwanted particulates. This is important in wood handling as the environments can be quite dirty. Figure 2 shows various vacuum inlet filters. Prefilters are also used in the wood industry to protect other components in the system. Prefilters are installed right after the vacuum cup or as close as possible to the application to filter out the air as early as possible before flowing through the system. A good exercise in wood applications is to oversize the filters so they can collect and handle more particulates. This allows for less maintenance and less potential flow restrictions.

Figure 2: Various vacuum filter models.

CONTROL VALVES Vacuum control valves come after the pump and filter. Vacuum valves are the controllers of the system that turns vacuum on by connecting the pump to the cups, which grips and holds the wood. When the valve position is switched off, it shuts off vacuum by blocking the vacuum source from the cups and exhausting vacuum in the cups to atmospheric air, which releases the wood. Figure 3 gives an example of a vacuum valve. Vacuum valves should be sized according to the application flow requirement and are an important justification for prefilters. In some applications, a vacuum valve can have a filter on its exhaust port since atmospheric air is sucked into the valve to release the product, which introduces unfiltered ambient air to the system. Venturis do not necessarily require a vacuum valve as they can be turned on and off with pneumatic valves.

Figure 3: Three-way vacuum valve ports.

NOVEMBER 2020

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LEVEL COMPENSATORS As we inch closer to vacuum cups at the end point of the system, level compensators come into play. Level compensators are spring loaded cup mounts that provide vertical compensation for the vacuum cups to establish a seal on the product surface. Level compensators are particularly useful for wood sheets that can bend and curve along the surface, creating different height points in local areas. The compensators allow the spring to compress and all cups to make contact against the surface. They are also used for machine height compensation for destacking applications. Compensators come in many thread sizes and stroke lengths. Figure 4 illustrates their functionality. Note that compensators should only be used in vertical lifting applications. They generally do not perform as well in shear or hold-down applications.

SUCTION CUPS Lastly, the vacuum cups seal against the wood surface and generate the gripping force. The cup diameter and final vacuum level determine the lifting force for each cup. The weight of the wood is rarely an issue as most wood applications offer significant surface area where cups can seal. A 4-inch (100 mm) diameter vacuum cup under 27 inHg (90% vacuum) has a theoretical lifting capacity of around 160 pounds. Assuming a safety factor of 4, that leaves us with about 40 pounds per 4-inch cup. Another example: a 6-inch (150 mm) cup under 15 inHg (50% vacuum) has a theoretical lifting capacity of approximately 200 pounds â&#x20AC;&#x201C; about 50 pounds after a safety factor of 4 is applied. Figure 5 demonstrates the applied lifting forces previously described. Vacuum cups should be sized correctly, but most importantly their material should be chosen wisely to ensure it is long lasting, nonmarking, and creates a good seal. Cup material selection will be discussed in more detail in the next few paragraphs.

6" (150mm) diameter cup 15"Hg vacuum level Holding force is 200lbs

4" (100mm) diameter cup 27"Hg vacuum level Holding force is 150lbs

Figure 5: Examples of vacuum cup lifting forces.

THE BASIC SYSTEM Now that we have defined our components, we can put together a schematic of a complete system, as shown in figure 6. This system excludes other potential components but provides a basic design for wood gripping. Vacuum sensors are useful for part presence by detecting the cups sealing or safety measures to ensure the vacuum level is high enough to proceed with the application. Pneumatic blow-off can be useful to provide a quicker or more aggressive product release. Blow-off can also be used to push away dust before the cups contact the wood. This helps with the seal and prevents more dust from entering the vacuum system. These components are not shown in figure 6.

Figure 4: Level compensators applied to sheet gripping.

R P A

Figure 6: Typical vacuum system schematic for wood pick & place, showing a pump, filter, valve, prefilters, level compensators, and cups.

Figure7: Cup models for gripping flat smooth wood surfaces.

FLAT AND SMOOTH SURFACES Flat and smooth surfaces are ideal for vacuum cup gripping. They provide an area for cups to seal with ease and allow for little to no leakage. Because of that, not a lot of flow is required from the vacuum pump, and so venturis or vane pumps are generally chosen as the source. The reduced leakage helps maintain higher vacuum levels for a confident grip and the need for less cups overall. Just about any vacuum cup could seal against such a surface, so in this case it is ideal to select a cup that is durable and nonmarking. Polyurethane material is a great choice that checks off both boxes but nitrile can also be an adequate selection. Flat cups typically offer longer life and overall gripping stability, though a single bellows model may be preferred for some height and angular compensation. Figure 7 gives examples of the cup options. These design approaches can be applied to wood surfaces with a little texture and curvature, within reason.

ROUGH OR TEXTURED SURFACES Rough or textured surfaces with more aggressive features introduce the possibility of air leaking into the system if the cups do not provide a near-perfect seal. There are two ways to compensate for the potential leakage. One way is to use a higher-flowing vacuum pump that removes the leaking air from the system at a faster rate than what is leaking through the cup seal and consequently increases the final vacuum level. This is a scenario in which a regenerative blower should be considered, although venturis and vane pumps can work depending on the severity of the leakage. The other approach is to use softer Durometer vacuum cups with thinner lips to allow the cups to conform better to the surface and reduce leakage. Sometimes rubber cups simply cannot offer a good seal without a very large pump, so a closed-cell foam cup is used instead as it can deform into the surface irregularities and offer a better seal than regular rubber cups. Foam can certainly be effective at sealing to surfaces, but the tradeoff is that it does not last nearly as long as a rubber cup. Foam wears away much quicker and can become a concern for maintenance teams and machine downtime. Therefore, foam cups should only be used if absolutely necessary. Figure 8 shows softer thin-lipped cups and foam seals. (Continued on page 8) WWW.IFPS.ORG â&#x20AC;˘ WWW.FLUIDPOWERJOURNAL.COM

Figure 8: Thin-lipped single bellows cup and foam seal profiles used on rough or textured surfaces. NOVEMBER 2020

cup seal

(Continued from page 7)

POROUS SURFACES Porous wood surfaces present a further challenge with vacuum gripping as leakage comes not only through the cup seal against the surface but also through the wood itself. So regardless of what cup model or material is being used, impactful leakage is unavoidable. Figure 9 illustrates this scenario. A suitable sealing cup, as discussed previously, can reduce leakage but cannot eliminate it entirely. Because of that, regenerative blowers are usually the preferred choice for porous surfaces and at times arguably the only choice for the system to work with a reasonable design. Although venturis and vane pumps can attain higher vacuum levels, the final vacuum levels are limited and even zeroed due to lack of flow. Zero vacuum is the result of the leakage flow being equal to the flow produced by the pump. In this case the pump cannot create a pressure differential (vacuum level). However, blowers provide relatively higher flows at deeper vacuum levels, and so the final vacuum level from a blower can be higher as a result of its flow capabilities. For sheet destacking of porous products, vacuum can sometimes pull through the wood and move the sheet below the top product being lifted. This can be prevented by using air knives between the sheets and side brushes or clamps for separation. Breaking the seal between two sheets can also be carried out by lifting one side slightly to peel off the top sheet.

NOVEMBER 2020

through work piece

Figure 9: Illustration of air leakage through the cup seal and porous wood.

The basic breakdown of a vacuum gripping system for wood includes the pumps, filters, valves, level compensators, and vacuum cups. Additional components such as sensors and blow-off valves are used based on preference and design needs. The wood surface texture and porosity determine the selection of the cup material and model, and different pump types and flow performances help generate acceptable vacuum levels. This article is a general guide and opinion piece. Professional assistance is recommended for specific application advice. ď Ź

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TEST YOUR SKILLS

10.00 FLUID POWER SYSTEMS Task 10.60: Describe the operation and application of electric flow control devices.

Flow control valves influence actuator speeds in a fluid power system. Increasing or decreasing the opening to

Outcome 10.60.1: Given the describes the and appliflow at a throttling point adjusts thefluid flow topower optimizeapplication; the system performance. This flowoperation at a throttling point may cation of hydraulic flow control devices. be calculated dependentelectric on the type of orifice, pressure drop, and the type of fluid. The electronic proportional flow

control is similar to standard two-port flow controls except the main control orifice is adjusted electronically. The Flow control valves influence actuator speeds in a fluidwith power system. Increasing or decreasing theof opening to control orifice has been modified to work in conjunction a force-controlled solenoid. If the position the spool flowisatmonitored a throttling adjusts the flow the system performance. This flow at athen throttling point withpoint a feedback device suchtoasoptimize a linear variable displacement transformer (LVDT), a strokemay be calculated dependent on the solenoid type of is orifice, drop and the type of fluid. The electronic controlled used topressure control the valve opening. proportional flow control is similar to standard two port flow controls except the main control orifice is adjusted electronically. The control orifice has been modified to work in conjunction with a force controlled solenoid. If the position of the spool is monitored with a feedback Specifically, two-port flow condevice asuch as proportional an LVDT pressure (linear compensated variable displacement trol valve has an electrically control orifice connected in to transformer) then aadjustable stroke controlled solenoid is used A2 the valve opening. series control with a hydrostat (essentially a pressure-reducing valve), as shown

in the illustration. Specifically, a two port proportional pressure compensated P1 Theflow hydrostat is located the main control orifice and control valveupstream has an of electrically adjustable control A is heldorifice open byconnected a light spring. input signal to the(essentially solenoid is a in When seriesthe with a hydrostat P2 P3 B zero, the light spring force holds the main orifice closed. When pressure reducing valve). See control Fig. 10.24. the solenoid is energized, the control orifice opens. When the solenoid The hydrostat is located upstream of the main control is open, the control orifice opens in proportion to the control signal and orifice and is held open by a light spring. When the input allows the oil to flow from port A to port B. Hydrostat signal to the solenoid is zero, the light spring force holds At the same time, the LVDT, if so equipped, provides the necessary 10.00 FLUID POWER SYSTEM the main control orifice closed. When the solenoid is feedback to hold position. In thisorifice case, the LVDT provides feedback to is energized, the control opens. When the solenoid Outcome 10.60.2: Given the fluid A3power application; describes the operation and appl maintain a very setting. open theaccurate controlorifice orifice opens in proportion to the control cation of pneumatic electric flow control devices. C Thesignal controland signal provides opening and of allows thetime-controlled oil to flow from port A toclosing B. An the electropneumatic proportional valve is an open loop flow control valve that controls the flow rate the orifice. For reverse free flow, a check valve may be built into accordance At the same time, the LVDT, if so equipped, provides thewith current through the coil. However, the system can incorporate a feedback loop as shown valve. Proportional flow control valves are available with either the linear example rpm Proportional of an air motor, Fig. 10.25. Fig. the 10.24 Pressure necessary feedback to hold position. In this case, the of a circuit controlling Proportional pressure-compensated flow control Compensated Flow Control or progressive flow characteristics. The input signal range is the same LVDT provides feedback to maintain a very accurate for both. However, the progressive flow characteristic gives finer control orifice setting. at the beginning of orifice adjustment. In case of electrical power or Power amplifier The control signal provides time-controlled opening and closing of the orifice. For reverse free flow, a check control feedback failure, the solenoid force drops to zero, and the force exerted (feedback circuit number of valve may be built into the valve. Proportional flow control valves are available with either linear or progressive circuit by the spring closes the orifice. Typically, when feedback wiring is conbuilt-in type) rotations flow characteristics. The input signal range is the same for both. However, the progressive flow characteristic nected incorrectly or damaged, the system uses an LED to indicate the gives finer control at the beginning of orifice adjustment. In case of electrical feedback power or feedback failure, the malfunction on the amplifier solenoid force dropscard. to zero and the force exerted by the spring closes the orifice. Typically, when feedback Some flow control valves consist of a proportional-force solenoid wiring is connected incorrectly or damaged, the and system has an LED (light emitting diode) indicating the tachometer a pilotmalfunction controller. Because thisamplifier valve is relatively on the card. unaffected by changes in system pressure, it can open and close the orifice in the same length Some flow control valves consist of a proportional force solenoid and a pilot controller. Because this valve is of time. This maximum time can be changed on the amplifier card by relatively unaffected by changes in system pressure, it can open and close the orifice in the same length of electro-pneumatic electropneumatic airadjusting motor a built-in ramp adjusting a built-in ramp generator. time. This maximum time can be changed on the amplifier card by generator. proportionalvalve valve proportional An electropneumatic proportional valve is an open loop flow control type, (flow two port) valve that controls the flow rate in accordance with current through the coil. However, the system can incorporate a feedback loop as shown in Controlling rotation of air motor the illustration of a circuit controlling the rpm of an air motor. Fig. 10.25 Controlling Rotation of Air Motor Under normal conditions, what directly controls the output rpm of the air motor? a. Supply pressure to the electropneumatic c. Dither level to the solenoid. proportional valve. d. Restrictions in the muffler. b. Flow rate through the electropneumatic e. None of the above. proportional valve. See page 31 for the solution. WWW.IFPS.ORG â&#x20AC;˘ WWW.FLUIDPOWERJOURNAL.COM

NOVEMBER 2020

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NOVEMBER 2020

COVER STORY

ELIMINATING WATER

contamination In the dog days of summer, people often say, “It’s not the heat, it’s the humidity.” This is true – on a hot day, it’s often the humidity that makes us suffer most. Unfortunately, pneumatic machinery also suffers from an increased likelihood of water in its air lines.

How water forms in air lines One of the most prominent triggers for excess water in pneumatic air lines is an increase in temperature. When temperatures rise, water evaporates and increases humidity, meaning there is a higher amount of water particles in the air. Since pneumatics rely on this air, it’s not surprising that systems release a significant amount of water during the hotter months. In fact, a 25-horsepower compressor can release more than 18 gallons of water in one day during the summer. Another trigger for excess water in an air line is fluctuation in air temperature. If the air temperature drops lower than its dew point (the atmospheric temperature at which water droplets can condense), water vapor condenses to form water. At this point, the relative humidity has essentially reached 100%. A typical example of this phenomenon is when, on a hot day, droplets form on a glass with cold drink. The same thing happens in pneumatic systems. Temperature fluctuations in day-to-day operations, or throughout the system itself, could potentially cause a similar “dew” to form within the system. If the air is carrying water vapor and goes from hot to cold within the line, vapor will condense to form water that will likely accumulate throughout the system. 12

NOVEMBER 2020

IN AIR SYSTEMS

By Michael Schapoehler, Product Technology Manager, Airline Hydraulics Corp.

It is a natural occurrence for water to be present in the air and fluctuate between its gas and liquid states. So why is it so harmful to pneumatic processes and machinery?

Bacterial growth. This moisture can also lead to the growth of bacteria and microorganisms in pipes and components. Some of these organisms can survive and multiply in higher temperature ranges, such as 45°C to 90°C (113°F to 194°F); others need lower temperatures, ranging from 25°C to 40°C (77°F to 104°F). However, the one thing they all need is moisture. Pneumatic lines can become breeding grounds for bacteria and mold that can gunk up components and cause health and safety concerns. Pipe scale and rust. Moisture also wreaks havoc on piping through the formation of pipe scale and rust. This buildup accumulates to decrease the pipe’s interior surface area, which increases the pressure loss as air passes through and reduces the system’s overall performance. Over time, the pipe scale and rust detach from the piping, traveling through the pneumatic system and causing further issues. Pneumatic components are intricate, precise, and relied on to make a pneumatic system run properly. When components become clogged with debris, a machine cannot operate at full capacity and may even

Why water must be removed Even a small amount of water within a pneumatic air line can result in big issues. Here are a few problems that occur when excess moisture goes unchecked. Loss of component lubrication. Pneumatic components are prelubricated at the factory. Water in a compressed air system compromises this lubrication and even has the potential to wash it away entirely. Unfortunately, many components rely on this lubrication to function correctly; without it, they are subject to premature wear and failure. It does not take much water to wash away the lubrication from smaller valves typically found in pneumatic systems. Within these components, rubber seals are prone to swelling, stiffening, and deterioration when subject to moisture.

A tiny valve can quickly become clogged with corrosion, rust, or pipe scale from water in an air line, leaving small components vulnerable to premature failure.

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fail completely. It may require shutdown to assess which component is failing and to then replace that component. Poor air quality for important processes. When compressed air is used directly in a product or process, it’s even more critical to remove moisture and its byproducts like bacteria, rust, and debris. In the simple process of cleaning parts and products using a blowgun, for example, a moist blast of air could carry rust, mold, and bacteria. Another process sensitive to the effects of water, bacteria, and particulate is a paint booth. Paint is precisely mixed with other chemicals to provide an aesthetic and protective coating to a product. If the pressurized air used to apply this finish is compromised, the impurities adversely affect its color, adherence, and quality. The painted item would be less protected from the elements and possibly suffer from premature wear. These are just two common processes that suffer from poor air quality, but there are many more depending on the application and industry. Increased costs. For original equipment manufacturers and machine builders, it’s costly to assume the end user will have clean, dry air flowing through the system. This assumption often results in premature wear and breakdown of the machine, which leads to increased time and resources to travel to the facilities, troubleshoot, and service the machines. End users need clean and dry air because they rely on the machine to operate without problems; their income often depends on it. At best, water damage will cause unplanned work stoppages to replace damaged components. At worst, it creates long downtimes to troubleshoot, source and purchase components, or get the machine serviced. If portions of the final product come into contact with moisture and debris from compressed air, latent damage and quality issues can occur. These scenarios all lead to reduced profits, which is especially harmful to businesses running off thin margins.

Create consistent temperatures. Pay attention to differences in temperatures within the system. Water vapors turn into liquid water when passing from a warmer to a colder area. Knowing this, design a pneumatic system to avoid these temperature changes. For example, air compressors are noisy, so designers may put them outside or in a non-temperature-controlled room away from the rest of the system. During the hotter months, that compressor delivers

hot compressed air to cold indoor areas. This setup is a recipe for condensation since warm air is running through cool pipes. By placing the air compressor in a similarly temperature-controlled room, the condensation may significantly reduce. Choose pipe material wisely. As noted earlier, water wreaks havoc on air piping and creates rust and scale. Carefully select pipe material to reduce these risks. Some materials, such as steel, are prone to rust and scale. (Continued on page 14)

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Removing water Here are a few best practices to decrease or prevent moisture accumulation. Drain the air compressor. Air compressor tanks often contain a drain at the bottom so that collected water can be released. Be sure to drain the tank after each use of the air compressor to prevent a consistent buildup of water. Drain the air compressor regularly, especially during the hotter months. If the air compressor is continuously under high demand, empty the tank frequently. WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

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(Continued from page 13) Other materials, such as marine-grade aluminum pipes, are more resistant to rust and help prevent oxidation-based contamination. Implementing a piping system with cleaner interior surfaces decreases issues related to moisture buildup and increases smooth, laminar airflow. Adjust piping direction. As water vapor condenses and becomes liquid, it typically collects and pools at the bottom of the pipe. One way to prevent this water from entering the rest of the system is to adjust where other pipes connect to the main line. Connecting these pipes to the top of the air line instead of the bottom, where the water collects, is likely to provide dryer air into the rest of the system. This method does not eliminate water but helps minimize damage that could occur further down the line.

Filter/regulators. A filter/regulator solution reduces water and debris. The AW30 by SMC works well if the system has high air flow. The AW30 uses a cyclone-effect to spin the air at high speeds, forcing the water and debris to the sides of the unit, where it becomes separated and drains out the bottom. This cyclone-effect does require a high amount of air pressure, so if this pressure is lacking, consider a different solution, such as a water separator. Water separators. Water separators come in a range of sizes to remove water from pneumatic lines. Smaller ones are good for point-of-use, and larger ones can serve as mainline filters. Part number Part description They are one of the most economical options SWINGFLGLCK2062 Swing hose FlangeLock kit for removing water from air lines. Air dryers. AirSWINGCAP2062 dryers are another option Swing circuit cap kit for keeping water out of pipes. Air dryers TRAVELFLGLCK2462 Travel hose FlangeLock kit can help a large facility experiencing water throughout its TRAVELCAP2462 air lines. Air dryers exist for Travel circuit cap kit more significant water removal issues, such Front attachment FRONTATTFLGLCK326162 FlangeLock kit as widespread rusting and corrosion of lines, FRONTATTCAP326162 Front attachment cap kit water spots from air tools, and liquid coming Boom arch hose from hoses and lines. BOOMARCHFLGLCK3262 FlangeLock kit There are two types of air dryers – desicBOOMARCHCAP3262 Boom arch hose cap kit cant and refrigerated. For refrigerated dryers, water condenses through the use of cooling

HITACHI FLANGELOCK AND CAP KITS AVAILABLE TM

Products to remove water from air lines If those best-practices aren’t applicable to a system or aren’t enough to prevent water accumulation, some products in the marketplace can help remove excess water.

temperatures, much like a refrigerator. As wet air comes into contact with the dryer, it is significantly cooled down, which turns the water vapor into liquid water that goes into a water-trap. Then the cold air heats back to room temperature, resulting in dryer air. A refrigerated air dryer works like a dehumidifier. Desiccant air dryers use absorptive materials, such as silica gel, to absorb the water vapor TM in the lines. The vapor then turns to liquid and sticks to the contents until they are cleaned out. With any air dryer, it’s essential to make sure the air pressure and capacity fit the compressor. Applicable machines Number of parts Weight (kg) Water in pneumatic air lines causes many EX3600, EX5600, that EX8000 can 16 x 2062U -aredbusiness’s FlangeLock 6.7 issues affect efficiency and bottom line.16 Implementing these EX3600, EX5600, EX8000 x 2062 - cap 4.5 cost-effective best practices and products EX3600, EX5600, EX8000 16 x 2462U - purple FlangeLock 7.7 can help achieve clean and dry air during every including EX3600, EX5600,season, EX8000 16 x 2462 -the cap hot and humid 6.4 months. For help which solution 14 x determining 3262U - black FlangeLock EX3600, EX5600, EX8000 8.9 4 x 3261U - black & silver FlangeLock is most useful, consult with a professional 14 x 3262 - cap EX3600, EX8000 9.5 to EX5600, determine the best option for a system’s 4 x 3261 - cap water removal 20needs.  EX3600, EX5600, EX8000 x 3262U - black FlangeLock 9.9

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11.3

CONTAMINATION CONTROL

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

CO U T CO NTA LTIM HE NT M A RO INA TE L T TI OO ON L

Stop the Mess

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The FlangeLock™ tool and caps are the ultimate contamination control tools for protecting your hydraulic system. The FlangeLock™ allows for the simple sealing of open hydraulic flanges without tools while the caps can be bolted in place of a flange connection. Easy on, easy off, they offer a leak-proof solution to hydraulic systems and environmental cleanliness. FlangeLock™ tools and caps stop the mess.

The FlangeLock™ Tool is the ultimate contamination control tool for protecting HITACHI MAKING systems. CONTAMINATION CONTROL EASY sealing of open SAE code 61, 62 your hydraulic It allows for the simple Hitachi have packaged FlangeLock™ tool and caps specifically for Hitachi mining excavators. The Hitachi customised & make CAT-Style hydraulic without Constructed from lightweight aluminum. kits sure no matter whichflanges component routine tools. maintenance is being performed on, you will always have the exact Easyofon, easy off.™*Offers to hydraulic system and environmental number FlangeLocks and capsatoleakproof help reducesolution contamination. cleanliness. FlangeLock™ Tools stop the mess! ™ *Note: FlangeLocks are not to be used under pressure

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NOVEMBER 2020

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

FIGURE IT OUT 3" B x 1" R x 15" STK

New Problem Cylinder Speed Increases on a Forming Press

1000 PSI Nitrogen Pre-Charge

FC-2

FC-1

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

Sol. 1A

Sol. 1B

Set at 2150 PSI

Robert Sheaf has more than 45 years troubleshooting, training, and consulting in the fluid power field. Email rjsheaf@cfc-solar.com or visit his website at www. cfcindustrialtraining.com.

0-3000 PSI

A FORMING PRESS had a 3-inch cylinder that increased its extension speed even when no one adjusted the meter-out flow control on the cylinder’s rod side. The customer asked us to check the accumulator’s nitrogen precharge to see if it was low. They knew that lowering the precharge pressure resulted in storing more oil in the accumulator. So they thought the nitrogen gas was leaking off, and they did not have charging equipment with gauges to check it. We told them they could check it by running the hydraulic pump until the system pressure reached 2,000 psi (138 bar), and then shut the pump down. We told them to slightly open the accumulator valve that dumps oil back to the tank and watch the gauge pressure as it slowly drops off. The pressure reading just before it suddenly drops to 0 psi would be awfully close to the gas precharge pressure. To their surprise, the pressure reading was close to the required 1,000 psi (69 bar). The customer did not know what to do. Do you?

Set at 2000 PSI

Automation · Controls · Process

Solution to October 2020 problem:

Airline Components for Clean, Dry, Air

Electric Motor Blowing Overloads Overloads on electric motors are sized to protect the motor. Overloads are caused either by excessive mechanical, flow, or pressure problems. The technician noticed that every time the failure happened, the pressure gauge bottomed out at 3,000 psi (207 bar). The 7½ HP motor with a pump delivering 10 gpm (38 lpm) reached maximum amperage at about 1000 psi (69 bar). When solenoid A is shifted, it opened the pilotoperated check to lower the basket. The flow requirement is very low and the pump is supposed to compensate, providing only the flow required at compensated pressure. We found that the pump compensator was sticking, causing the pump to act like a fixed-volume pump. We also found the safety relief screwed all the way into its maximum of 3,200 psi (221 bar). We confirmed that it was the pump by adjusting the relief to 1,000 psi (69 bar), and the maximum 20-amp rating was not exceeded. Visit www.fluidpowerjournal.com to view previous problems.

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A complete line of Filters, Regulators, Lubricators as well as combination units to meet every need. Mainline Filters and Moisture Removal filters also available

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www.mainmanufacturing.com Main's website provides quick access to the 120 page catalog that includes popular styles of MAIN Manufacturing’s extensive offering of carbon and stainless Hydraulic Flanges and Components – ready for immediate shipment. Metric ordering information, weld specs, and dimensional information included. The “Quick Reference Guide” helps specify less popular items often stocked or quickly manufactured (generally 3-4 days) at our US plant. “Create-AFlange” offers more parts than the catalog — by picture. If it’s not here, or for questions, E-mails may be sent to get your answer quickly.

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I F P S U P D AT E

CELEBRATING 60 YEARS

IFPS Charts 2021 Projects

IFPS HELD ITS 2020 annual meeting virtually on Sept. 25. The board of directors approved a number of projects by the education, marketing, membership and certification committees for 2021: • The upgraded Mobile Hydraulic Mechanic certification is in its final stages of development. Areas of the MHM Study Manual that were added and improved include: » Principles of operation explained for commonly found components within a mobile hydraulic system – pumps, valves, actuators, and accessories » Color-coded cutaway illustrations of hydraulic components to aid in understanding operation » Symbology updated to conform to ISO 1219 standard » Expanded content on troubleshooting to include decision-tree aids » Detailed content on pressure, flow, and directional control valves

» Improved graphics throughout and many real-life photos to assist in visualization » Basic hydraulic calculations useful in troubleshooting » Safety tips » Basic principles of electrohydraulic control – open loop and closed loop » Electrohydraulic valves » Sensors used in electrohydraulic systems • Mentorship Program – A subcommittee will explore mentorship opportunities and the creation of a mentorship program. • Nontechnical Associate Certification – A subcommittee will begin writing a study manual for a nonspecialist certification for those who communicate fluid power information such as product part numbers, standard options, promotions, and available services. The Fluid Power Associate certification requires a written test. This certification will be geared toward inside sales, customer service, parts personnel, clerical and support staff, and

entry level positions. The subcommittee is seeking active certified professionals for technical writing. • Fluid Power Symbols Library – A subcommittee will investigate offering the fluid power symbols library to our members. To become involved in a committee or shortterm subcommittee, contact akayser@ifps.org.

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NOVEMBER 2020

I F P S U P D AT E

CELEBRATING 60 YEARS

IFPS Announces 2021 Officers TALKING ABOUT IFPS

THE INTERNATIONAL Fluid Power Society is pleased to announce that Rocky Phoenix, CFPMMH, was elected 2021 president and chair during the IFPS annual meeting. Rocky is the 61st president of IFPS and will take office along with the 2021 board of directors in January. Rocky served as IFPS membership vice president and is a member of the Fluid Power Hall of Fame selection committee. He has been involved in the fluid power industry for 15 years with Open Loop Energy, Winnemucca, Nevada, working in the mining industry. Rocky is a graduate of North Seattle College, where he earned an associate’s degree in industrial drafting and design. His previous work experience includes many years in the motorcycle and automotive industries. He is an active private pilot. “I am both excited and honored to be elected president by the IFPS membership for 2021,” Rocky said. “I anticipate a progressive and exciting time ahead for our membership, even in this unique and trying time in our history. I look forward to the progress we will make going forward working with the most knowledgeable and passionate membership I know of in any industry.”

The following officers were confirmed at the meeting: First Vice President: Denis Poirier, Jr., CFPAI/AJPP, CFPHS, CFPIHM, CFPCC – Eaton Corporation Immediate Past President: Jeff Kenney, CFPIHM, CFPMHM, CFPMHT – Dover Hydraulics South Treasurer: Jeff Hodges, CFPAI/AJPP, CFPMHM – Altec Industries Vice President Certification: James O’Halek, CFPAI/AJPP, CFPMIP, CMPMM – The Boeing Company Vice President Marketing and Public Relations: Scott Sardina, PE, CFPAI, CFPHS – Waterclock Engineering Vice President Education: Randy Bobbitt, CFPAI, CFPHS – Danfoss Power Solutions Vice President Membership: John Bibaeff, PE, CFPE, CFPAI, CFPS 18

NOVEMBER 2020

IFPS welcomes the following new directors-at-large: Jon Rhodes, CFPAI, CFPS, CFPECS – CFC Industrial Training Steve Bogush, CFPAI/AJPP, CFPHS, CFPIHM – Poclain Hydraulics

The following directors-at-large were reconfirmed at the annual meeting: Stephen Blazer, CFPE, CFPS, CFPMHM, CFPIHT, CFPMHT – Altec Industries Chauntelle Baughman, CFPHS – OneHydraulics Cary Boozer, PE, CFPE – Motion Industries Lisa DeBenedetto, CFPS – GS Global Resources Daniel Fernandes, CFPECS, CFPS – Sun Hydraulics Brandon Gustafson, PE, CFPE, CFPS, CFPIHT, CFPMHM – Graco Garrett Hoisington, CFPAI/AJPP, CFPS, CFPMHM – Open Loop Energy Brian Kenoyer, CFPHS – Five Landis Corp. Mohaned Shahin, CFPS – Parker Hannifin Randy Smith, CFPHS – Northrop Grumman Corp.

Honorary directors-at-large and ex-officio were reconfirmed at the annual meeting: Ex-officio – Donna Pollander, ACA, Executive Director Elizabeth Rehfus, CFPE, CFPS Paul Prass, Fluid Power Journal Robert Sheaf, CFPAI/AJPP, CFC Industrial Training Special thanks to outgoing past president Timothy White, CFPAI/AJPP, CFPS, CFPECS, CFPMIH, CFPMMH, CFPMIP, CFPMT, CFPMM, of The Boeing Company, and outgoing vice president of education Kenneth Dulinski, CFPAI/ AJPP, CFPECS, CFPHS, CFPMIH, CFMMH, CFPMT, of Macomb Community College, as they complete their tenures on the IFPS board. Their many years of service, commitment, and expertise helped steer the society in its mission.

How and why did you get involved in IFPS, and what have you gained personally and professionally? Years ago, I noticed the certification initials on a colleague’s business card. Recently I was reminded that if I only look at a problem from one perspective, my potential solutions are limited. Only looking within my own industry wasn’t using the full potential of fluid power. So I chose to get involved in IFPS to broaden my knowledge base. John Bibaeff Jr. PE, CFPE, CFPAI, CFPS I am a strong proponent of lifelong learning. Whether it is through certification, technical training, or academia, continual education is a key part in maintaining relevancy in the workplace. As a professional trainer, certification sends a clear message to those within the industry that a neutral third party has validated my baseline skill sets, both as an instructor and hydraulics professional. Denis M. Poirier Jr. CFPAI/AJPP, CFPHS, CFPIHM I became involved in IFPS so that I can help others get the same feeling of accomplishment that I received years earlier. This was my way of giving back to the industry. Robert Post, CFPHS

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

I F P S U P D AT E

Hydraulic and Pneumatic Specialist Study Group Web Seminars

WHILE THE NATION was hunkered down during quarantine, Tom Blansett, CFPAI, Dan Helgerson, CFPAI, and Ernie Parker, CFPAI, were busy conducting free biweekly online study groups. These recorded presentations are available to IFPS members and are especially helpful to those preparing for a certification test. Visit ifps.org/web-seminars to register and view the presentations and others on safety, pneumatics, actuators, hydraulic valves, electrohydraulics, contamination control, pumps, and more. Registration is free for members. HYDRAULIC SPECIALIST STUDY MANUAL WEB SEMINARS Outcome 1.2.3: Understand the application of valves – Part 1 Outcome 1.2.3: Understand the application of valves – Part 2

Outcome 2.2.3: Understanding the principles of levers Outcome 3.1.4: Calculate the thrust for a toggle mechanism Outcome 3.1.5: Calculate the hydraulic pressure to support jib boom loads Outcome 3.4.3: Understand the application of logic elements (cartridge valves) Outcome 3.5.1: Calculate the capacity of a reservoir using volume requirements Outcome 3.5.2: Understand the limitations of the reservoir for fluid conditioning Outcome 3.6.1: Understand the difference between isothermal and adiabatic conditions Outcome 3.6.2: Understand the purposes of the accumulator Outcome 3.9: Specify heat exchangers

PNEUMATIC SPECIALIST STUDY MANUAL WEB SEMINARS Outcome 1.9: Understand supply side air preparation Outcome 3.12: Understand moisture control Outcome 3.19: Understanding critical flow velocity and sonic conductance Outcome 2.3: Understanding moving loads with friction and incline factors Outcome 3.10: Size and select vacuum pads Outcome 3.18: Calculate the kinetic energy required to stop a load with a shock absorber Outcome 4.3: Familiarization with ladder logic diagrams

CERTIFICATION EMPOWERS CONFIDENCE

August 2020

Newly Certified Professionals ACCREDITED INSTRUCTOR AUTHORIZED JOB PERFORMANCE PROCTOR AUTHORIZED JOB PERFORMANCE CC PROCTOR

Mark Fiore, Rio Controls & Hydraulics Michael O’Connor, Northwestern Michigan College Bradley Wagner, Manitowoc Crane Group CONDUCTOR & CONECTOR (CC)

Michael Butler, The Boeing Company Nicholas Danielson, The Boeing Company Nicholas Hoffman, The Boeing Company Keith Houser, The Boeing Company Jason Moore, The Boeing Company HYDRAULIC SPECIALIST (HS)

Matthew Lilyquist, Altec Industries, Inc. Rudy O’Brien, Altec Industries, Inc. Ben Wagener, Altec Industries, Inc. MOBILE HYDRAULIC MECHANIC (MHM)

Shawn Atcher, Altec Industries, Inc. Jesse Bartholomew, Altec Industries, Inc. Eric Brady, Altec Industries, Inc. Gregory Burnette, AEP Charles Collins, Altec Industries, Inc. Kameron Connell, Crossroads Mobile Maintenance WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

Tyler Coppage, Altec Industries, Inc. Seth Cossey, Altec Industries, Inc. Ryan Cristofaro, Altec Industries, Inc. Marc Czulewicz, Altec Industries, Inc. Myron Dennis, Altec Industries, Inc. James Depratter, Altec Industries, Inc. Jessy Frisk, Altec Industries, Inc. Daniel Gulley, Altec Industries, Inc. Joshua Holmes, Crossroads Mobile Maintenance Tyler James, Altec Industries, Inc. Gilbert Kessler, Altec Industries, Inc. Kevin Lonsway, AEP William Lucas, Altec Industries, Inc. Robert McCoy, Altec Industries, Inc. Justin McCrabb, Crossroads Mobile Maintenance Robert Merrow, Altec Industries, Inc. Jason Mishler, Crossroads Mobile Maintenance Tucker Moss, Altec Industries, Inc. Aaron Moussette, Tip Top Aroborists Richard O’Brien, Crossroads Mobile Maintenance John Paholsky, AEP Mark Peavley, Altec Industries, Inc. Randall Riggs, Altec Industries, Inc. Colt Seaver, Altec Industries, Inc.

Before I earned my certification, I thought I knew fluid power design. After earning my certification, I know that I know Fluid Power. Marti Wendel, CFPAI, CFPE, CFPS

Clifford Shamblin, AEP Dirk Sims, Crossroads Mobile Maintenance Ryan Stinde, Altec Industries, Inc. Carl Stone, Altec Industries, Inc. Michael Sullivan, AEP Devon Warman, Altec Industries, Inc. Geoffrey Watson, Altec Industries, Inc. Jack Whalen, Crossroads Mobile Maintenance NOVEMBER 2020

I F P S U P D AT E

Certification Testing Locations Individuals wishing to take any IFPS written certification tests can select from convenient locations across the United States and Canada. IFPS is able to offer these locations through its affiliation with The Consortium of College Testing Centers provided by National College Testing Association. Contact headquarters if you do not see a location near you. Every effort will be made to accommodate your needs. If your test was postponed due to the pandemic, please contact headquarters so that we may reschedule.

TENTATIVE TESTING DATES FOR ALL LOCATIONS: December 2020 Tuesday 12/1 • Thursday 12/17 January 2021 Tuesday 1/12 • Thursday 1/28 February 2021 Tuesday 2/2 • Thursday 2/25 March 2021 Tuesday 3/2 • Thursday 3/25

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CELEBRATING 60 YEARS

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I F P S U P D AT E

AVAILABLE IFPS CERTIFICATIONS CFPAI Certified Fluid Power Accredited Instructor CFPAJPP Certified Fluid Power Authorized Job Performance Proctor CFPAJPPCC Certified Fluid Power Authorized Job Performance Proctor Connector & Conductor CFPE Certified Fluid Power Engineer CFPS Certified Fluid Power Specialist (Must Obtain CFPHS & CFPPS) CFPHS Certified Fluid Power Hydraulic Specialist CFPPS Certified Fluid Power Pneumatic Specialist CFPECS Certified Fluid Power Electronic Controls Specialist CFPMT Certified Fluid Power Master Technician (Must Obtain CFPIHT, CFPMHT, & CFPPT) CFPIHT Certified Fluid Power Industrial Hydraulic Technician CFPMHT Certified Fluid Power Mobile Hydraulic Technician CFPPT Certified Fluid Power Pneumatic Technician CFPMM Certified Fluid Power Master Mechanic (Must Obtain CFPIHM, CFPMHM, & CFPPM) CFPIHM Certified Fluid Power Industrial Hydraulic Mechanic CFPMHM Certified Fluid Power Mobile Hydraulic Mechanic CFPPM Certified Fluid Power Pneumatic Mechanic CFPMIH Certified Fluid Power Master of Industrial Hydraulics (Must Obtain CFPIHM, CFPIHT, & CFPCC) CFPMMH Certified Fluid Power Master of Mobile Hydraulics (Must Obtain CFPMHM, CFPMHT, & CFPCC) CFPMIP Certified Fluid Power Master of Industrial Pneumatics (Must Obtain CFPPM, CFPPT, & CFPCC) CFPCC Certified Fluid Power Connector & Conductor CFPSD Fluid Power System Designer CFPMEC (In Development) Mobile Electronic Controls

Tentative Certification Review Training In-house Review Training – an IFPS Accredited Instructor will come to your company (minimum 10 individuals) HYDRAULIC SPECIALIST (HS) CERTIFICATION REVIEW Onsite review training for small groups – contact kpollander@ifps.org for details March 23-26, 2021 - Fairfield, OH - CFC Industrial Training | Written test: March 26, 2021 September 13-16, 2021 - Fairfield, OH - CFC Industrial Training | Written test: September 16, 2021 PNEUMATIC SPECIALIST (PS) Onsite review training for small groups – contact kpollander@ifps.org for details December 14-16, 2020 - Fairfield, OH - CFC Industrial Training | Written test: December 17, 2020 July 27-29, 2021 - Fairfield, OH - CFC Industrial Training | Written test: July 29, 2021 ELECTRONIC CONTROLS (ECS) CERTIFICATION REVIEW Onsite review training for small groups – contact kpollander@ifps.org for details August 9-12, 2021 - Fairfield, OH - CFC Industrial Training | Written test: August 12, 2021 CONNECTOR & CONDUCTOR (CC) CERTIFICATION REVIEW Onsite review training for small groups – contact kpollander@ifps.org for details May 18-19, 2021 - Fairfield, OH - CFC Industrial Training | Written and JP test: May 20, 2021 November 16-17, 2021 - Fairfield, OH - CFC Industrial Training | Written and JP test: November 18, 2021 MOBILE HYDRAULIC MECHANIC (MHM) CERTIFICATION REVIEW Onsite review training for small groups – contact kpollander@ifps.org for details Online Mobile Hydraulic Mechanic Certification Review (for written test) offered through info@cfcindustrialtraining.com. This course takes you through all chapters of the MHM Study Manual (6.5 hours) and every outcome to prepare you for the written MHM test. Members receive 20% off. (Test fees are additional - separate registration required.) April 13-15, 2021 - Fairfield, OH - CFC Industrial Training | Written and JP test: April 16, 2021 August 30 - September 1, 2021 - Fairfield, OH - CFC Industrial Training | Written and JP test: September 2, 2021 INDUSTRIAL HYDRAULIC MECHANIC (IHM) CERTIFICATION Onsite review training for small groups – contact kpollander@ifps.org for details June 14 - 16, 2021 - Fairfield, OH - CFC Industrial Training | Written and JP test: June 17, 2021 INDUSTRIAL HYDRAULIC TECHNICIAN (IHT) CERTIFICATION REVIEW TRAINING Onsite review training for small groups – contact kpollander@ifps.org for details Call for dates. Phone: 513-874-3225 - CFC Industrial Training, Fairfield, Ohio MOBILE HYDRAULIC TECHNICIAN (MHT) CERTIFICATION REVIEW TRAINING Onsite review training for small groups – contact kpollander@ifps.org for details Call for dates. Phone: 513-874-3225 - CFC Industrial Training, Fairfield, Ohio PNEUMATIC TECHNICIAN (PT) and PNEUMATIC MECHANIC CERTIFICATION REVIEW TRAINING Onsite review training for small groups – contact kpollander@ifps.org for details Call for dates. Phone: 513-874-3225 - CFC Industrial Training, Fairfield, Ohio JOB PERFORMANCE (JP) TRAINING Onsite review training for small groups – contact kpollander@ifps.org for details Online Job Performance Review - CFC Industrial Training offers online JP Reviews which includes stations 1-6 of the IFPS mechanic and technician job performance tests. Members may e-mail askus@ifps.org for a 20% coupon code off the list price or get the code in our Members Only area for the entire IFPS Job Performance Review; test not included. LIVE DISTANCE LEARNING JOB PERFORMANCE STATION REVIEW Onsite review training for small groups – contact kpollander@ifps.org for details E-mail info@cfcindustrialtraining.com for information.

CFPIEC (In Development) Industrial Electronic Controls

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NOVEMBER 2020

very day, hydraulic cylinders work to push, pull, tilt, raise, and hold loads on diverse equipment. Often the operator is responsible for gradually stopping the cylinder in a controlled manner. However, in some applications, the cylinder may fully extend or retract and reach the end of the mechanical stroke, but it is not stopped by the operator. This likely is not a problem if the speed is slow. If there is a high-inertia load, when the cylinder reaches the end of stroke the sudden stop can cause mechanical shock, with effects ranging from mild annoyance to serious risk.

HYDRAULIC CYLINDER CUSHIONS

Photos Credit: Electro Hydraulic Machinery

FIGHT MECHANICAL SHOCK

By Tony Casassa, Application Engineer, Aggressive Hydraulics

Inertia is a product of mass and speed. Consider a hydraulic cylinder pushing or pulling a wheeled cart horizontally. When the cylinder moves slowly and reaches end of stroke, the change of speed is small and does not cause any problems. If the hydraulic flow increases and the cart moves at a higher velocity, the inertia increases, and the resulting potential shock at the end of stroke also increases. Because the cart has wheels and is moving horizontally, increasing the mass of the cart will cause only a small increase in the pressure required to move the cart, but it will cause a larger increase in the inertia. Now imagine the cylinder moving the cart up an incline. The pressure required to move the load is higher. When the cylinder reaches the end of stroke, the pressure still increases to the system maximum, but the increase is smaller; therefore, the shock is 22

NOVEMBER 2020

A strong shock at the end of cylinder stroke can damage machine components, negatively affect machine performance, or present a risk to the machine operator. less. On the other hand, if the cylinder moves the cart down an incline, the inertia will increase, and the shock will be higher. Another example is a hydraulic cylinder opening and closing a swinging gate around a pivot point. Typically, the cylinder is mounted near the pivot point and provides a relatively high force and short stroke. Due to mechanical advantage, every inch of cylinder travel multiplies into a longer distance for the gate's edge.

The wider the gate, the further the edge is from the pivot point, and therefore the higher the rotational inertia of the gate. A strong shock at the end of cylinder stroke can damage machine components, negatively affect machine performance, or present a risk to the machine operator. When the load moved by a cylinder comes to a sudden stop, stress is applied to the cylinder and the machine's mechanical structure. Excessive stress on these structural components and pressure spikes in hydraulic tubes or hoses can cause premature failure. Shock can also degrade machine productivity. For example, if a cylinder is moving a load of aggregate material, it may cause some of the material to fall out of the bucket or container. Of highest importance is the potential risk to the

operator. For example, the operator in an aerial work platform requires the cylinder to come to a slow, controlled stop. Historically, the responsibility would be on the operator to slow and stop the cylinder to prevent any undesirable shock. Now there is increasing market demand for user-friendly machines, and industry and safety regulations place more responsibility on the machine designer. In some cases, the best solution is the addition of switches or sensors to detect cylinder position, a proportional hydraulic valve to control the flow, and a programmable logic controller to read the input and determine

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the output. However, due to cost, serviceability, or operating environment, the electronic solution may not be suitable.

END-OF-STROKE CUSHIONS Hydraulic cylinders with endof-stroke cushion features have been available for many years, with the most familiar being spear-type cushions, which are common in tie rod construction cylinders but also used on welded construction cylinders.

Figure 1: A. Cast-iron piston ring, B. Axial holes, C. Cross-drilled hole

Spear-type cushions. Spear-type cushions can be nonadjustable, but more often they’re adjustable. This type of cushion can be effective, but it also has some shortcomings to consider. Because the design has a spear or sleeve that enters and exits a concentric pocket, if the difference between the spear and pocket diameter is too small, there is a risk of metalto-metal contact and galling. On the other hand, if the clearance is too large, the effective orifice will be too large, and the cushion will be ineffective. A downside from the design standpoint is that the cushioned flow has two parallel paths. Oil flows through the annular area created by the spear and pocket as well as across the fixed orifice or adjustable needle valve, resulting in a complex scenario for predicting the flow. The spear-type design requires space in the head and end cap for the cushion-adjusting needle valve and the check valve for incoming flow. Lastly, although the ability to adjust the cushion may have advantages in some circumstances, it also allows the possibility of incorrect adjustment; for example, an operator seeking to improve productivity without understanding the potential negative consequences. Cushion piston. The cushion piston is an alternate solution to provide the cushion function and offers advantages over the spear-type cushion. This solution can be designed for a wide range of flows and can be more effective in a lower flow range than the spear type. The controlled flow

Figure 2

Figure 3 Illustrations: Aggressive Hydraulics

passes through a single orifice, which allows more predictable cushion performance. The orifice and the check valve function are built into the piston, requiring no further space increase than the length of the cushion zone, keeping the cylinder compact in size. It is nonadjustable, which prevents the possibility of malfunctions caused by improper adjustments.

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As the name suggests, the features that provide the cushion effect are built into the piston. On the outside diameter of the piston, in addition to the typical bidirectional elastomeric piston seal, a cast-iron piston ring is added in each direction the cushion is desired, either on the blind end for a cushion at full retract, on the rod end for a cushion at full extend, or both as shown in figure 1.

The groove for the cast-iron piston ring is wider than normal, allowing it to shift slightly in the groove. In addition, on each end of the piston there is a series of axial holes and a single cross-drilled hole. These features do not affect the cylinder operation during most of the stroke. Flow can freely enter and exit the cylinder, and the elastomeric piston seal prevents internal leakage. The cast-iron ring can “float” in the wide groove, and the pressure is the same on both sides of the ring. When the cast-iron ring passes the port, the exiting flow is forced through the axial and cross-drilled holes, creating a pressure drop. With higher pressure on one side, the ring is forced to the opposite side of the groove, and flow must pass through the single cross-drilled hole. If properly sized, the orifice controls the flow rate of oil exiting the cylinder. The pressure of the incoming fluid increases until it reaches the maximum level, as determined by the setting of a component outside the cylinder, commonly a relief valve or a controller on a variable displacement pump. The relief valve must open to divert the flow that cannot enter the cylinder, or the pump displacement must decrease to reduce the flow (figure 2). Although the cushion may be desirable to slow the cylinder at the end of stroke, when the direction is reversed it is preferred for it to operate immediately at a normal speed. This is the reason the groove for the cast-iron ring is wider than normal. Just as the pressure drop of the exiting flow moved the cast-iron ring to one side of the groove, now the pressure drop of the entering flow moves it to the opposite side. The flow can now pass under the cast-iron ring and out the axial holes with minimal or no restriction. This feature is referred to as fast start-up. After the cast-iron ring passes the port, fluid flows directly into the cylinder, and once again, the cushion features do not affect performance until the next time it reaches the end of stroke (figure 3). (Continued on page 24) NOVEMBER 2020

Figure 4 Illustration: Aggressive Hydraulics

(Continued from page 23) When working with cylinders with any cushion, it is vital to consider the possibility of pressure intensification. To reduce the cylinder speed, the exiting flow must be restricted so that the incoming flow reaches the maximum pressure. However, because of the area difference on each side of the piston, the exiting flow will not be the same pressure as the incoming flow. On the extend side, also known as the blind or cap end, the fluid under pressure acts on the full bore diameter of the cylinder. On the retract or rod side, the fluid under pressure does not act on the center area because of the rod; it only acts on the annular area between the rod and the bore. The ratio of the extend area to the retract area is known as the cylinder ratio. The cylinder ratio is typically in the range of 2:1 to 3:1, but if the rod is large relative to the bore, it can be as high as 10:1 (figure 4).

If the pressure is controlled by a main system relief set at 3,000 psi (207 bar) and the cylinder has a ratio of 2:1, when the cylinder is retracting and the cushion is active, the rod side pressure increases to 3,000 psi (207 bar). Because the extend side area is greater by a factor of two, the resulting pressure on the extend side is calculated by dividing by two, or 1,500 psi (103 bar). This pressure is used to design the control orifice size in the piston for the designed flow rate. If the same cylinder has a cushion at full extend and the extend side pressure increases to 3,000 psi (207 bar), the resulting pressure on the rod side is 6,000 psi (414 bar). This higher pressure is completely contained within the cylinder and is not measured with a cylinder port gauge, nor can it be prevented or limited with the addition of an external relief valve.

Air Compressors

Clean Dry Air Improves Performance... Clean, Dry Compressed Air Starts with The Extractor/Dryer® Manufactured by LA-MAn Corporation • Point of Use Compressed Air Filter to Improve and Extend Equipment Life • Removes Moisture and Contaminates to a 5-Micron Rating: Lower Micron Ratings are Available • Models with Flow Ranges of 15 SCFM to 500 SCFM Rated Up To 250psi are Standard • Differential Pressure Gauge Built in • Mounting Hardware Included for Easy Installation • Weep Drain is Standard; Float Drain or Electronic Drain Valves Optional

NOVEMBER 2020

In addition to using this pressure to determine the orifice diameter, this higher pressure must also be considered when selecting seals, tube-wall thickness, and head retention methods to prevent cylinder failure. If the cylinder has a relatively large diameter rod and therefore a high cylinder ratio, even at low system pressures it may not be economically feasible to design the cylinder for the resulting rod-side pressure. It may be necessary to add a relief valve set at a lower pressure specifically for the extend side of the cylinder. If that does not provide adequate extend force, the cylinder may not be a good candidate for a cushion at full extend, and deceleration should be accomplished by a different method. Although removing the potential for incorrect adjustment may be a benefit in some applications, in others the benefits of adjustment outweigh the risk. For these applications, it is possible to adapt the cushion piston design to accommodate an adjustment valve in the end cap or head gland. As with all hydraulic components, the introduction of a control orifice makes it more sensitive to contamination. A small partiHydraulic cle can lodge in cylinders with the orifice and block or restrict end-of-stroke flow, negatively cushion features affecting cushhave been ion performance. available for It is important many years, with for proper operthe most familiar ation and long life to maintain a being spear-type high level of fluid cushions. cleanliness via proper filtration. A race car on a track can stop one of two ways. If the driver applies the brakes, the reduction in speed is controlled and gradual as the brakes convert the energy to heat and the heat is dissipated. If the car hits the wall, the change in speed is abrupt and violent. The car will likely sustain mechanical damage as it absorbs the change in energy. A welded cylinder with a properly designed cushion piston is analogous to properly applied brakes, as the energy is transferred to hydraulic heat and the cylinder stops in a controlled manner. This can provide a significant benefit to the machine and the user. 

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Liquid Level Switches Liquid Level Switches are designed to shut down machinery or turn on warning devices when liquid supply recedes to a predetermined level. They can be wired to flash warning lights, sound howlers, shut down machines, or signal computers. This is especially helpful in unattended automated plants. Available with a housing for external mounting or without housing for internal applications. Oil-Rite Corporation PO Box 1207 Manitwoc WI 54221-1207 Phone: (920) 682-6173 Email: sales@oilrite.com www.oilrite.com

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Stop The Mess!

SAVE

Call you local Hitachi Muswellbrook representative or • No tools required TIME • No expensive thehardware branchneeded on 02 6541 6300 forSAVE more information. • No more rags stuffed into hoses MONEY • No more messy plastic caps SAVE • The ultimate contamination control tool LABOR • One hand installation SAVE • Eliminate hydraulic oil spills & clean up OIL • Quick installation & ease of usage • Safe for personnel & environment • Industry acclaimed For more information, call 203-861-9400 or email sales@flangelock.com. www.flangelock.com

NOVEMBER 2020

SPECIAL AD SECTION

Vac Cubes Multi Venturi Vacuum Pumps With over 30 years of proven results Vac Cubes and our multi stage venturi vacuum pumps are a great fit for your vacuum application. They are designed to provide higher vacuum flows with less air consumption. Multiple models available with maximum vacuum up to 27”hg and vacuum flows up to 25CFM and the ability to manifold together.

info@vac-cube.com 727.944.3337 www.vac-cube.com

Introducing—9S Series Investment Cast Swivels The "9S" Series swivels represent one of the most complete range of sizes and configurations available to industry. This series has been redesigned to incorporate a one-piece barrel arrangement, thus eliminating the need for braze joints. These swivels are pressure balanced with operating pressures up to 5,000 psi. All configurations are designed with a 4:1 Safety Factor and include RoHS compliant zinc plating.

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

P.O. Box 6479 • Fort Worth, TX 76115 V. 817/923-1965 • www.hydraulicsinc.com

Now Available! Full MTRs and Lot Traceability MAIN Manufacturing Products, Inc. now offers full MTRs and lot traceability on all common flanges. Carbon, stainless, and coppernickel alloy are available. If not part of our 7000+ in-stock products, MAIN can manufacture and ship quickly. 4-5 days is common from our US facility. MAIN Manufacturing Products, Inc. Phone: 800.521.7918 • E-mail: info@mainmfg.com

NOVEMBER 2020

Proportional Directional Flow Control Valve PWK10 Series Screw-in cartridge, solenoid operated, 4-way, 3-position, direct acting spool • 350 bar, 36 L/min • Available in closed and motor spools • 1000 hours salt fog rust protected • 28W, IP69K ingress protected • Repeatability / Linearity within 3%

HYDAC Technology Corporation – Hydraulic Division 630.545.0800 www.HYDAC-NA.com

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SPECIAL AD SECTION

Stainless Steel Check Valves, Thread-in Type

Go ahead. Push me. Ordinary heavy duty not heavy enough?

INSERTA® IGT (Stainless Steel) Guided Disc Thread-in Type Check Valves can be inserted in manifolds, subplates, flanges, and integrated valve systems for use up to 6000 psi. Their compact geometry allows for flexible design options. The patented guided disc design provides superior resistance to wear in conditions prone to significant turbulence, high flow transients, or high cycling. Valve discs and seats are hardened and flat lapped for positive fluid shut off. The valve disc may be provided with a customer specified orifice to provide fixed orifice flow control function in the checked direction. Thread sizes from 7/16-20 to 1-5/16-12 typically ship from stock.

Heavy-Duty Mill Cylinders for: • Induction-Hardened, Chrome-Plated Rods • Heavy Wall Tubing • Replaceable Glands & Retainer Rings • High-Load Piston Design Think indestructible and call Yates. www.yatesind.com

Contact us to showcase your products and services in the Product Spotlight. This special section is a high-profile area offering productspecific advertising. Visit fluidpowerjournal.com for more information or to view our media guide.

Yates Industries (HQ) 586.778.7680 Yates Cylinders Alabama 256.351.8081 Yates Cylinders Georgia 678.355.2240

INSERTA® PRODUCTS BLUE BELL, PENNSYLVANIA, USA www.inserta.com

Yates Cylinders Ohio 513.217.6777

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

New Switches and Sensors from Norstat

NORSTAT INC. RECENTLY introduced two new products that add to its lines of safety switches and vacuum and pressure sensors. The new S-type, master coded, RFID safety switch for high-risk safety applications is electronically operated. As a stand-alone safety switch, it is designed to work with any safety relay. The S-type switch uses a unique, frequency operated, switching system ensuring that only an S-type actuator can be used to complete the switch-stopping operation, thereby preventing any unauthorized attempt at overriding the switch. The electronic design provides precision switching and on-switch indication for reliable operation. For high-risk applications, the switches offer excellent protection against manipulation, interference, or tampering. Norstat’s line of vacuum and pressure sensors now has a new IO-Link interface. IO-Link is a manufacturer-independent, globally standardized, bidirectional, digital point-to-point interface through which a controller can easily communicate with sensors and actuators. Using extensive data, industrial processes can be monitored and controlled in detail and in real time. An intelligent interface such as IO-Link is essential in collecting data and allowing flexibility and control during production. The IO-Link can be easily integrated into existing systems, as it requires no special demands on wiring or mounting and runs via unshielded cables and standard industrial connectors.

WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

NOVEMBER 2020

Optimizing Efficiency to Meet

Emmissions Regulations By Dierk Peitsmeyer, Product Portfolio Manager Bucher Electronics

The European Union has stipulated that CO 2 emissions must be significantly reduced. Provisions such as the EU’s Green Label initiative and Germany’s Energy Efficiency Strategy 2050 will have a major impact on technical development in the next few years. Designers will increasingly rely on highly efficient drive systems with alternative and hybrid drives. These changes also affect mobile machines; they will likely be equipped with

NOVEMBER 2020

battery-powered electric drives, fuel cells, or diesel generators. Hydraulic systems will require more efficient components and systems for precision movements.

Challenges for drive technology For companies to work economically, electrically driven mobile machines must fulfill some important criteria. Machines must be designed to achieve sufficiently long

operating times without tedious recharging and to work reliably and quickly at high power levels, similar to former machines. Companies also demand low noise emissions and low energy consumption and maintenance costs.

Efficiency the primary factor Sufficient operating time can be achieved with a large dimensioned energy source or with a system with low power dissipation.

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

However, this results in high expenses for the components. Using efficient components or systems can prove to be useful. Additionally, they reduce the need for cost-intensive energy. Electric drives already have a high efficiency over a wide operating range. Nevertheless, the hydraulics used today in mobile machines powered by diesel engines are not efficient enough. Improved systems need to be installed.

Limits of existing hydraulic systems Hydraulic systems that adapt to the current volume and pressure requirements with the aid of variable displacement pumps, so-called load sensing (LS) systems, are not optimal for electrified machines. The noise emissions of conventional variable displacement axial piston pumps are too high. They will be particularly prominent in electrified machines due to the absence of diesel-engine noise. The level of efficiency of LS systems is not optimal throughout the entire operating range. The control deviation causes unnecessary losses in most operating points. Significant damping is occasionally necessary to operate the LS system without oscillation. This extends the response time considerably. Consequently, it is not advantageous to replace the diesel engine with an electric motor and leave the existing hydraulic system unchanged.

Inadequate electromechanics Replacing hydraulic cylinders with electromechanical linear drives has proven to be impractical. The mechanical gearboxes are not suitable for the high loads of a construction machine. Furthermore, every electromechanical linear drive requires an electric motor with correspondingly high power. The installed power will be quite high in total, even though it is never needed at the same time.

For precision movements, valve controls with flow on demand (FOD) are an economical alternative. Hydraulic control blocks with separate control edges, such as the LVS12 valve from Bucher Hydraulics, reduce power loss and enable movements to be more dynamic, further increasing the effectiveness of the machine. It is possible to combine variants of electric drives and hydraulic systems optimally in an electrical system with a DC intermediate circuit. For example, the hydraulic pump can be operated as a fixed clearance pump with variable speed. The speed of the electric motor must be set accordingly. Bucher Hydraulics’ FOD software makes this possible without additional effort for the hydraulics user. The system calculates the required optimum speed based on the valve actuation characteristics. The result of the FOD system is always the lowest possible pressure at the pump. It depends on the current load and pressure losses. Pressure losses can be minimized by optimizing the system design. It is particularly advantageous that the control pressure difference required in the LS system is eliminated. In the FOD system, the valve opening and pump speed are controlled simultaneously. As a result, the responding behavior is very fast and direct, comparable to the performance of electric travel drives. The control system stablizes without oscillations. This allows the operator to drive the machine more effectively. The FOD system also offers additional advantages for controlled functions, such as the assistance control systems. Bucher Hydraulics’ FOD software features additional options that are not available with a traditional LS system.

It is not advantageous to replace the diesel engine with an electric motor and leave the existing hydraulic system unchanged. operating range. This minimizes the need for costly battery capacity and extends the achievable service life. Reducing power dissipations at the hydraulic pump, for example, from 5 kW to only 2.5 kW, contributes significantly to the energy-efficient operation of the machines. The efficiency chain further enhances this effect. Especially suitable for such drive combinations are the AX series hydraulic pumps from Bucher Hydraulics. Even at high performance, the noise level is low and pleasant, as expected by end users. The pumps can be started at high pressure and operated at very low speed without premature and excessive wear. Due to low leakage and the high number of pistons, a smooth cylinder movement can be achieved even at low speeds. This is particularly beneficial for positioning work and large booms. The design principle with consistent hydrostatic relief of the components makes these pumps particularly reliable. 

More efficient ‘flow-on-demand’ hydraulics As a favorable compromise between high efficiency and low cost, an optimized hydraulic system can be used. Closed-circuit displacer controls are an excellent choice for high-performance functions with a high potential for energy recovery. These are the ones with the lowest energy losses. Each linear function requires a combination of an electric motor and a pump, comparable to electromechanical linear drives. It does not make sense for all functions. WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

Pump efficiency is crucial In variable speed operations, the pump is of particular importance to meet the special requirements of an FOD system. The pump is the heart of the system. Comparable to the efficiency of high-quality electric motors, it must be operable at 92% to 94% efficiency over a wide NOVEMBER 2020

STEPPER TECHNOLOGY BOOSTS FIREFIGHTING EFFICIENCY

lames begin to blaze and a fire engine pulls up within minutes, complete with professionals ready to help. The focus in an emergency is usually on crew response time, but what about their equipment? Is it also optimized to complete the task as quickly as possible when lives and property are at stake? One area with potential for improvement concerns foam systems used for fire and combustion suppression. For many reasons, foam has been the fire-suppression agent of choice for flammable and combustible liquids. Foam is used to cool the fuel surface and saturate flammable materials, preventing reignition of fuel vapors while also preventing additional oxygen from reaching the fire. A foam solution typically consists of three ingredients: water, foam concentrate, and air. Depending on the situation, fire crews are responsible for mixing, metering, and aerating these ingredients to correctly produce the required amount of foam solution with the appropriate dilution rate. For example, 6% concentrates are mixed with water at a ratio of 94 parts water to 6 parts foam concentrate. This means 94 gallons of water is needed for every 6 gallons of foam concentrate. When mixing 3% concentrate, the correct mixture is 3 gallons of foam concentrate with 97 gallons of water. Both foam solutions provide the same performance characteristics. But a 3% foam concentrate is more concentrated than the 6% concentrate, requiring less product to produce the same result. Common practice is to minimize the amount of foam concentrate needed to produce a foam solution. This allows the fire crew to maximize its storage space and either double its firefighting capacity or reduce the amount of foam used without compromising suppression capacity. Lower proportioning rates can reduce the cost of foam-system components and concentrate transportation. Many critical variables come into play when obtaining the right mixture. It can be challenging when the job requires a wide operating range, such as controlling flow rates of 0.125 gpm (4 lpm) at 75 psi (5 bar) up to more than 90 gpm (340 lpm) at 250 psi (17 bar). Most flow meters can’t deliver accurate measurements across such a large range. To make matters worse, some truck manufacturers use valves with fixed orifices that require manual adjusting to reduce or increase the amount of foam concentrate in the line.

NOVEMBER 2020

By Pat Byce, Marketing Coordinator, Spartan Scientific Spartan Scientific encountered this issue when working with a global fire truck manufacturer. The original equipment manufacturer had been using an old design that required three separate valves with fixed orifices to output various required foam concentrates. Spartan knew there had to be a way to use foam more efficiently while reducing the time it takes to extinguish fires.

ADVANCED STEPPER TECHNOLOGY With breakthroughs in self-contained media-separated electronic proportional flow control valves, also called stepper valves, Spartan immediately knew these devices could offer a solution. Previously, achieving proportional control in electrically actuated valves with closed loop systems meant spending thousands of dollars on parts from multiple suppliers. Today’s stepper valves bring a new approach to controlling liquids and gases. For example, Spartan’s stepper valves are self-contained with control circuitry (including an M12 connector) embedding the motor and valve into the unit. Users can control flow rates automatically in an all-in-one, plug & play, readyto-go device that eliminates the need to purchase a separate control unit, which can compromise performance and add significant expense. With multiple positions (or steps), Spartan’s newest rendition precisely regulates flow output and only draws current when a change to media flow is required, maximizing energy savings. The stepper’s onboard internal feedback constantly monitors the valve position. The elliptical shape of the tip is designed to create linearity in the change of flow rate brought on by the change in position of the valve stroke. The poppet has a

specialized elliptical profile contour that protects the valve’s mechanical workings as it produces a linear flow through the precise valve orifice. Control can be tailored to increase resolution. The ability to move in so many small steps allows an unprecedented level of reliability and repeatability.

A PERFECT FIT FOR FIRE TRUCKS Spartan replaced all three of the truck manufacturer’s valves with one stepper valve. We were able to design a stepper valve that could accommodate the flow rates required for fire applications, from 0.125 gpm (4 lpm) to 90 gpm (340 lpm) for pressures ranging from 0 to 250 psi (17 bar) with a 1-inch (25-mm) orifice. The valve seat serves as both a positive stop and flow control for the fluid media, allowing fire crews to obtain a precise flow rate over thousands of positions, rather than the limited number of combinations from several fixed orifices. The valve’s multiselection controller can directly communicate with a highway-addressable remote transducer-enabled flow meter, allowing the valve to accurately monitor and control the flow of media. This allows the truck operator to choose the percentage of foam on the fly in response to a firefighter’s command. Furthermore, closed loop feedback makes the stepper valve intelligent. It uses information from the flow meter to learn the desired settings and automatically open and close the valve along with changes to overall system operation, such as increases or decreases in pressure and varying pumps, to bring the flow back into the desired range. Auto-adjusting to compensate for fluctuations in flow during foam and water dispensing allows the valve to compensate for addition or subtraction of auxiliary fire hoses. This maintains the preset percentage of foam concentrate and conserves the amount of foam dispensed. The truck manufacturer saw a huge cost and weight savings with this design. Greater precision and quicker adjustments offers first responders a more effective solution. While the truck manufacturer and firefighters were thrilled with the improvement, stepper technology is beneficial for any application that requires accurate control of chemicals, such as car washes, general manufacturing, medical, food and drug, drinking water, agriculture, and fluid-temperature control. With today’s advanced stepper valves, applications are only limited by your imagination. 

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

CL ASSIFIEDS

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almomanifold.com

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Phone: 989.984.0800 Toll Free: 1.877.ALMO. NOW Fax: 989.984.0830

Huge Inventory. Ships Same Day! Quality Products. Interchangeable Design.

877-245-6247 HYDRAULIC FLANGES and COMPONENTS THE “SPECIAL” YOU WANT IS PROBABLY ON OUR SHELVES MAIN Mfg. Products, Inc. 800.521.7918 fax 810.953.1385 www.MAINMFG.com/fpj

The correct answer to Test Your Skills on page 9 is b.

ADVERTISER INDEX Company.................................................Page.................................Phone....................................................... Web AGI - American Grippers Inc............................. 10........................ 203-459-8345....................................................................... .................................................................................................www.agi-automation.com/product-category/o-ring-assembly Aignep USA..................................................... 8, 11........................ 615-771-6650.................................. www.aignepusa.com Bimba Manufacturing Company.......Inside front........................ 800-442-4622............................... www.bimba.com/airos CFC-Solar............................................................ 31.....................1-513-874-3225............................cfcindustrialtraining.com Clippard Instrument Lab Inc............................. 10........................ 877-245-6247.......................................www.clippard.com Emerson Automation Solutions/ASCO....... 5, 16.................... 1 888 889 9170......................... emerson.com/automation Flange Lock.................................................. 14, 25........................ 203-861-9400.................................. www.flangelock.com Flow Ezy Filters Inc............................................ 25....................... 1-88-237-1165............................. www.flowezyfilters.com HYDAC Technology Corporation...................... 26........................ 630-545-0800................................ www.HYDAC-NA..com Hydraulics, Inc.............................................. 17, 26........................ 817-923-1965..............................www.hydraulicsinc.com Inserta Products........................................... 25, 27........................ 215-643-0192 ........................................ www.inserta.com La-Man Corp................................................. 16, 24........................ 800-348-2463 ..........................................www.laman.com Lubriplate, Inc.......................................Back cover........................ 800-733-4755.................................... www.lubriplate.com Main Manufacturing Products Inc............. 16, 26.....................1-800-521-7918...............................www.mainmfg.com/fpj MOCAP INC........................................................ 26........................ 800-633-6775 ........................................ www.mocap.com Oil-Rite Corp........................................................ 25........................ 920-682-6173...........................................www.oilrite.com Peninsular Cylinder Co. Inc............................... 13.....................1-800-526-7968...................www.peninsularcylinders.com Proportion Air Inc............................................... 11........................ 877-406-3215....................................... ProportionAir.com SMC Pneumatics Inc..................................... 3, 15........................ 800-762-7621.......................................www.smcusa.com Texcel.............................................Inside back, 16.....................1-800-231-7116............................... www.texcelrubber.com Vac-Cubes..................................................... 17, 26........................ 727-944-3337.....................................www.vac-cube.com Yates Industries Inc....................................... 1, 27........................ 586-778-7680......................................www.yatesind.com WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

NOVEMBER 2020

SUBSCRIBE BY MAIL FILL OUT THIS CARD COMPLETELY, DETACH, AND MAIL OR FAX IT TO START YOUR SUBSCRIPTION MAIL TO: PO BOX 2548 • ORLANDO, FL 32802-9830 • FAX: 1-866-207-1450 YOU CAN ALSO SUBSCRIBE ONLINE AT WWW.FLUIDPOWERJOURNAL.COM. 01  YES! Please start/continue my complimentary subscription to the Fluid Power Journal Signature (required)

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2. What is your primary job title? (check only one) 10  Administration: Chairman, President, V.P., Secretary, Treasury, General Manager, Owner, Business Manager, Director, etc. 11  Plant Operations: VP of Manufacturing/ Operation/ Production, Plant Management/ Director/ Manager/ Supervisor/ Superintendent/ Foreman/ Safety Director, etc. 12  Engineering: V.P. Eng., Eng., Design Eng., Director of Eng., Staff Specialist, Chief Eng., Senior Eng., Maintenance/Production Eng., etc. 13  Technical: Chief Tech., Fluid Power Tech., etc. 14  Mechanical: Chief Master Mech., Master Mech., Fluid Power Mech., etc. 15  Purchasing: VP/Director of Purch., Procurement Manager, Buyer, Purch., etc. 16  Other: (please specify)_________________________________________________________________________________________________ 3. Number of employees at this location? A  1-19 B  20-49 C  50-99

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4. What is the primary business activity at this location? In the Fluid Power Industry, Outside the Fluid Power Industry 56  Manufacturer 57  Distributor 58  Education 59  Original Equipment Manufacturer (OEM) 61  Other: (please specify)__________________________________________ 5. Which of the following best describes your market focus? A  Aerospace A  Marine & Offshore Equipment B  Agricultural Machinery B  Material Handling Equipment C  Automotive C  Mining Machinery D  Civil Engineering D  Packaging Machinery E  Cranes E  Plastic Machinery F  Drills & Drilling Equip. F  Presses & Foundry G  Flame Cutting/Welding Equip. G  Railroad Machinery H  Food Machinery H  Road Construct/Maint. Equip. I  Forestry I  Simulators & Test Equipment J  Furnaces J  Snow Vehicles, Ski Lifts K  Gas & Oilfield Machinery K  Steel Plants & Rolling Mills L  Heavy Construction & Equip. L  Truck & Bus Industry M  Military Vehicles M  Textile Machinery N  Construction & Utility Equip. N  Woodworking Machines O  Machine Tools O  Other (specify)_____________ P  Government Related P  Fluid Power Industry

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MAKING A DIFFERENCE

FOR YOUR BUSINESS Our cutting-edge line of hydraulic hose and fittings is not just a product division. Itâ&#x20AC;&#x2122;s a promise of superior service, quality, technical support and availability. Weâ&#x20AC;&#x2122;ve built our company on impeccable customer service. Let us know how we can make a difference for your business. call 800.231.7116 or email sales@texcelrubber.com

Lubriplate ®

ADVANCED 100% SYNTHETIC HYDRAULIC FLUIDS FROM A COMPANY ADVANCING LUBRICATION FOR 150 YEARS

QUALITY INNOVATION

150 years ago, our founders set out to make the highest quality, best performing lubricants available. In doing so, they helped pioneer the use of anti-wear additives that significantly increased lubricant performance through the years. Today, that innovative tradition continues with our newest line of ultra high-performance, 100% synthetic hydraulic fluids. These new lubricants provide a wide range of benefits including: extended fluid change intervals, cooler operating temperatures, reduced friction and reduced downtime.

PERFORMANCE FOR 150 YEARS

Products include...

SYN LUBE SERIES 32 -68 • High-Performance, 100% Synthetic, Polyalphaolefin (PAO)-Based Fluids. • Provides Extended Drain Intervals and Excellent Compatibility with Seals. • Available in ISO Viscosity Grades 32, 46 and 68.

SFGO ULTRA SERIES 7- 68 • NSF H1 Registered and NSF ISO 21469 Certified - Food Machinery Grade. • High Performance, 100% Synthetic PAO-Based Fluids. • Available in ISO Viscosity Grades 7, 15, 22, 32, 46 and 68.

SYNXTREME FRH1- 46 • High-Performance, FM Approved, Fire Resistant Hydraulic Fluid. • NSF H1 Registered and NSF ISO 21469 Certified - Food Machinery Grade. • ECO-Friendly, Readily Biodegradable (OECD 301F).

150

CELEBRATING

YEARS

OF QUALITY, INNOVATION AND PERFORMANCE

LUBRIPLATE LUBRICANTS COMPANY

NEWARK, NJ 07105 / TOLEDO, OH 43605 / 800-733-4755 LubeXpert@lubriplate.com / www.lubriplate.com

INCLUDED AT NO ADDITIONAL CHARGE

Lubriplate’s

ESP

Complimentary Extra Services Package COLOR CODED LUBE CHARTS & MACHINERY TAGS PLANT SURVEYS / TECH SUPPORT / TRAINING LUBRICATION SOFTWARE / FOLLOW-UP OIL ANALYSIS

Fluid Power Journal November 2020

Articles inside

Hydraulic Cylinder Cushions Fight Mechanical Shock Sudden stops add stress to a machine and its cylinders

Stepper Technology Boosts Firefighting Efficiency With lives often on the line, stepper valves fine-tune the water-and- foam mix that chokes the flames

Optimizing Efficiency to Meet Emissions Regulations Designers cope with demands for lower noise levels and fuel consumption

Cover Story

Test Your Skills