Fluid Power Journal October 2021

OCTOBER 2021

Lubrication Management Grows Up

fluidpowerjournal.com

VALVES FOR PRESSURE REGULATION

P.24

SIZING RODLESS PNEUMATIC ACTUATORS P.18

Innovative Designs & Publishing • 3245 Freemansburg Avenue • Palmer, PA 18045-7118

MANAGING FLUID CONTAMINATION

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IN THIS ISSUE

OCTOBER 2021

VOLUME 28 • ISSUE 10

Features

18

6 Damage Control: Managing Fluid Contamination in Hydraulic Systems Strategies to monitor and remove the inevitable particle ingress that affects the bottom line.

10 The Unvarnished Truth: Contamination Control Makes Servo Valves Click Weekly machine trips were causing hours of downtime for a tissue manufacturer.

18 Cover Story Take Measures: Ten Tips for Sizing Rodless Actuators Why it matters to make the most accurate selection possible.

6

22 Test Your Skills

Selecting Vacuum Pads 24 Family Friction: Lubrication Management Grows Up The field is in its infancy, but its long-term benefits are clear.

24 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.

26 Absolute Advantage: Proportional Valves for Pressure Regulation Some electronic regulators still use solenoid valves, which can cause various issues.

Departments 4

Notable Words

5 12 28 31

Figure It Out IFPS Update Product Spotlight Classifieds

COVER PHOTO courtesy of Tolomatic.

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CONTAMINATION CONTROL

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

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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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OCTOBER 2021

3

N OTA B L E WO R D S

Leaping into Digital Asset Tracking

By Nicole Forbes, Senior Global Product Manager, Danfoss

»

IMAGINE WALKING INTO your local library and being directed to a card catalog to find the book you’re after. Or watching your doctor page through paper files to determine when you’re due for a procedure or vaccine. The delight of nostalgia might soon degenerate to frustration as a process that should have taken seconds eats into your day.

Such systems might seem ancient in today’s digital world. In reality, they’re similar to, if not more advanced than, some of the processes we still rely on in hydraulics. Consider hose replacement, for example. Typically, it involves an end user bringing a hose assembly to a distributor and waiting for a bill of materials to be correctly identified. It’s not just a hassle; while the hose is in the distributor’s hands, the machine isn’t operating. In addition, an identical replacement isn’t always a guarantee!

Out with the old Some companies have turned to tracking methods like paper-based systems or simple software solutions to overcome these challenges. But these measures can be time consuming, and they have their limitations.

First, it’s not easy to organize, store, and gain insights from volumes of physical records. There’s ample room for human error and misplaced documentation. These systems also don’t automate preventative maintenance processes. If inspections are missed and a hose fails, not only is a safety hazard created, but the end user might face downtime, lost profits, and fines.

Thankfully, there are more efficient and reliable methods available to manage and track assets.

In with the new Hydraulic asset tracking systems allow users to label important parts and track them via a centralized digital system. Key documents such as certifications and bills of material can be electronically attached to physical products, making time spent chasing paperwork a thing of the past. Big data reporting capabilities simplify preventative maintenance and the discovery and diagnosis of issues. For example, if a system tells a user a certain hose has been replaced multiple times in a 12-month period due to wear, it may indicate that a more abrasion-resistant material is warranted. The simple scan of a barcode unlocks more information about a hose assembly than a physical inspection could yield.

Asset tracking isn’t a new technology, but recent advancements have made such systems more robust and easier to adopt, with preloaded product specifications, simple user interfaces, customizable labels, and more cost-effective fee structures.

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OCTOBER 2021

Take the leap So, why the holdout? Certainly there’s an argument to be made about time commitment.

It’s true that setting up templates takes time.

Once complete, however, tracking becomes easier and faster than other methods. The initial time investment pays dividends in the long run. If cost is a factor, try comparing systems with different pricing models, such as one-time fee, annual subscription, or per-license charge.

We’re in the midst of an inevitable transition to digital tracking systems, making it imperative to diligently weigh objections against the risk of losing business opportunities. We’re already seeing OEMs require asset-tracking capabilities on projects they put out for bid. We also see asset tracking being closely tied to e-commerce and thoroughly integrated into numerous aspects of manufacturing, assembly, and testing processes.

The entire industry benefits from digitizing asset tracking. End users can enhance safety through automated maintenance alerts. They also benefit financially by increasing uptime. Distributors remain competitive simply by having such a system, and they see financial benefits through the ease of ordering replacement parts. Each entity improves their customer experience through seamless information sharing.

Into the future In a digital age in which we expect instant information from the machines and products around us, hydraulic components should be no exception. The advent of Industry 4.0 and digitally trackable assets allow distributors, OEMs, and end users to experience a fully connected environment. We live and breathe these benefits in our daily lives. Our refrigerators tell us when we need more milk. Our mobile phones tell us when to leave for an appointment. It’s time to bring hydraulic asset tracking into the digital age. Only then can we maximize application performance, reliability, and safety.

•

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FIGURE IT OUT

PUBLISHER Innovative Designs & Publishing, Inc. 3245 Freemansburg Avenue, Palmer, PA 18045-7118 Tel: 800-730-5904 or 610-923-0380 Fax: 610-923-0390 • Email: Art@FluidPowerJournal.com www.FluidPowerJournal.com

Founders: Paul and Lisa Prass

Associate Publisher: Bob McKinney Editor: Michael Degan

Technical Editor: Dan Helgerson, CFPAI/AJPP, CFPS, CFPECS, CFPSD, CFPMT, CFPCC - CFPSOS LLC Director of Creative Services: Erica Montes

Account Executive: Norma Abrunzo 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 2021 BOARD OF DIRECTORS

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

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

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

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

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

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

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

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

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

Executive Director: Donna Pollander, ACA

Communications Director: Adele Kayser

Technical Director: Thomas Blansett, CFPS, CFPAI

Assistant Director: Stephanie Coleman Certification Coordinator: Kyle Pollander

Bookkeeper: Diane McMahon

Administrative Assistant: Beth Borodziuk

Fluid Power Journal (ISSN# 1073-7898) is the official publication of the International Fluid Power Society published monthly with four supplemental issues, including a Systems Integrator Directory, OffHighway 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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New Problem

Valve Flaw Leads to Faulty Pressures

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

»

THE CIRCUIT BELOW was working for several years when the pressure-reducing valve on the clamp cylinder started leaking oil into an assembly bolt cavity. It appeared that a casting flaw finally failed after thousands of pressure cycles. The company purchased and installed a new module. However, the cap end would see full system pressure crushing the product while the rod side pressure would see reduced pressure as designed.

Maintenance returned the valve and replaced it with a new one, but it had the same problem. They examined the old valve and confirmed the new ones had the same model number as the failed one.

What was the problem?

Solution to the September 2021 problem:

Regenerative Circuit Drops Out

The regen circuit that did not work properly until the hinged fixture arm was about halfway up was caused by the spring drain line connected internally. Any pressure in the spring chamber of pressure controls is additive to the valve’s pressure setting. The pressure needed to lift the hinged fixture continually decreased as the fixture was raised. Externally draining the rod side counterbalance valve solved the problem.

To view previous problems, visit www. fluidpowerjournal.com/figure-it-out.

M

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.

OCTOBER 2021

5

By Tom Fistrovich, OEM and Mobile Market Business Development Manager, Des-Case Corporation

DAMAGE CONTROL

Managing Fluid Contamination in Mobile Hydraulic Systems

or companies that rely on mobile equipment as part of their normal operations, reduction in both downtime and overall maintenance costs is imperative to maintaining fleet efficiency and profitability. The harsh environments in which mobile equipment is typically used can make these reductions extremely challenging. On the drive side, there is an increasing trend toward electric drive versus conventional diesel powered. However, hydraulic systems continue to be a critical component in mobile equipment. While there are many aspects to maintaining a reliable hydraulic operation, contamination ingression in the form of particles and moisture is a major source of poor reliability, leading to underperformance, component damage, and hydraulic system failures.

Mobile equipment can be used and operated in some of the most challenging and contaminated working environments, including mine sites, agricultural plots, steel mills, oil fields, and many other applications. They all have one thing is common: unplanned downtime due to contamination affects operational efficiency and throughput, ultimately reducing the bottom line. Unfortunately, operating in these contaminated environments is unavoidable. Consumer demand for natural resources and products manufactured on these work sites continually increases.

But there is a way to reduce the negative impact of contamination on hydraulic systems in mobile equipment.

Most fluid power experts recognize that particle contamination is responsible for as much as 80% of mechanical machine wear in hydraulic systems. In light of these challenges, improving overall system cleanliness reduces hydraulic system failures, helping to increase equipment reliability while reducing the costs associated with maintenance and downtime. Fortunately, there is a surefire way to achieve this. Proactive maintenance of hydraulic fluid can extend the system life as much as five times. Extending hydraulic fluid and system life extends the time the mobile equipment is in use and doing its job.

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OCTOBER 2021

Figure 1: Fluid cleanliness target levels. (Recommended testing methods: optical particle count [ISO 11500] for both hard and soft particle counts; Karl Fischer method for moisture level.)

Figure 2: Measuring particle contamination in an oil.

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Setting a strategy The first step is to establish a maximum target for fluid cleanliness using ISO 4406 or a similar fluid-cleanliness standard. Based on the sensitivity of hydraulic components like pumps and valves, different components can tolerate varied amounts of contamination. Knowing the sensitivity level allows equipment manufacturers and users to set target cleanliness levels. In fluid power systems, hydraulic pumps, motors, and valves typically drive the cleanliness requirements of the system, as these components are very sensitive to contamination and deposits. As shown in figure 1, a hydraulic system using a vane pump is less sensitive to the concentration of particle contamination than a system using a variable volume piston pump.

Furthermore, the addition of servo valves to the system makes it even more sensitive to particle contamination. Knowing which components exist in your hydraulic system allows you to set a baseline cleanliness level at which the system should operate. A precision fluid contamination control strategy strives to achieve and maintain these baseline contamination levels.

Once the user determines a target cleanliness level, the next step is to consider a strategy to control the contamination and maintain system cleanliness to the target levels. A precision fluid contamination control strategy is the most holistic method to achieve and maintain the target levels.

This method of proactive maintenance revolves around four areas: • Contamination prevention – sealing and protecting the system • Contamination removal – cleaning and purifying the fluid system • Fluid assessment – visual assessment and review of the fluid during operation • Fluid monitoring – using condition-based monitoring to diagnose fluid condition and contamination levels Contamination prevention. Studies show that contamination exclusion in a system can cost 10 times less than contamination removal in the same system. This is one driving factor for implementing the first state of a precision strategy: contamination prevention. Mobile hydraulic systems have many points that potentially allow contamination ingression into the system. Common ingression points include the hydraulic cylinders and reservoirs.

While contamination ingression at the hydraulic cylinders typically happens during operation or washdown, it is common for the hydraulic reservoir to experience contamination ingression during operation and service intervals.

Contamination prevention in a hydraulic system starts with assuring that the system’s hydraulic WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

fluid meets the recommended ISO 4406 target cleanliness level. Hydraulic fluids can become contaminated even before they arrive on site.

In fact, every transfer of the fluid can double its contamination level. New hydraulic fluid should be filtered prior to adding it to a system because most new hydraulic fluids are up to 16 times dirtier than typical cleanliness targets (see figure 2).

Users should verify that they are adding the correct fluid to prevent cross-contamination. Whether the hydraulic fluid is stored in bulk tanks, left in drums, or stored into intermediate bulk containers, the storage system and dispensing equipment should

Figure 3: Airflow of a desiccant breather.

be equipped with some level of loop filtration to continually clean the fluid when filling, recirculating, and dispensing it. Mobile filtration carts are an excellent choice for servicing on-site mobile equipment hydraulic fluids, as they offer the necessary fluid filtration and the convenience of mobility.

In a hydraulic system reservoir, one common point of contamination ingression is the breather.

Breathers are a necessary component in many hydraulic systems to allow air to freely flow in and out of the system as fluid levels change or thermal expansion or contraction causes air exchange. Most standard breathers offer a pleated filter to prevent particle contamination. These breathers are generally limited to exclusion of contamination particles of about 20-40 microns absolute. Some hydraulic

components can experience damage from particles under 2 microns. Additionally, standard pleated breather filters do not typically address the risk of moisture ingression, which can enter through the breather due to moisture or humidity in the operating environment. It can also develop in the reservoir’s headspace due to repeated changes in relative humidity.

To address moisture and particle contamination during operation, users should consider desiccant breathers for all hydraulic reservoirs. Desiccant breathers work by filtering particle contaminants and absorbing moisture when the breather inhales air (see figure 3). Desiccant breathers also help remove moisture from the reservoir’s headspace through designs that keep the desiccant in constant contact with it.

Contamination removal. Even after taking the proper steps to prevent contamination, it will inevitably enter a hydraulic system at some point in the operational life. This is why hydraulic systems on mobile equipment typically employ some level of filtration through the pressure and flow of the system. Common filtration setups consist of an in-tank strainer or suction filter screen, filtration on the system’s pressure side, and a return-line filter to clean the fluid as it returns to the reservoir.

However, these components by themselves are often insufficient to maintain optimum levels of fluid cleanliness.

One very efficient and effective way to improve cleanliness levels is with a kidney loop filtration system, which is typically set up as an off-line system and consists of its own motor, pump, and filter elements. Off-line kidney loop systems can be set up on mobile filter carts and incorporated into a work site’s preventative maintenance. While the kidney loop is one of the most efficient ways of removing contamination, mobile equipment is typically limited to using it when the equipment is idle or being serviced. But the goal of precision contamination control strategy is to reduce mobile equipment’s idle and service time. Kidney loops also do not clean the fluid in the hose cylinders and valve blocks as the machine sits idle.

There are, however, options that function as a kidney loop filtration system and are specifically designed for mobile equipment. An example is a bypass filtration system. Bypass units take advantage of hydraulic system pressure and flow by bleeding 5% to 10% of fluid from the main hydraulic system, often via a pilot circuit, and passing it through one or more filter elements before the clean fluid returns to the reservoir (see figure 4).

Since a bypass filter is not part of the main fluid flow path, bypass filters can be installed with high filtration efficiency, often exceeding a filtration beta rating of 2,000 at 3 microns.

Assess and monitor. To ensure that contamination control measures are effective, regular routine fluid analysis is critical. Sampling oil monthly or (Continued on page 8) OCTOBER 2021

7

(Continued from page 7) every 1,000 operating hours – whichever comes first – should include not just basic oil analysis but also confirmation that contamination levels are meeting the ISO 4406 standard. Users should investigate levels above the defined targets and take corrective action as soon as possible.

Another tool is condition-based monitoring, which provides feedback on sudden changes in the fluid and indicates a need for service or

replacement. For example, users can integrate an oil-quality sensor into the hydraulic system to alert for oil degradation and provide the amount of remaining useful oil life. Pairing condition-based monitoring with an oil-sampling strategy can extend maintenance intervals, improve equipment reliability, and reduce the need for costly fluid changes, unplanned downtime, waste-fluid costs, the carbon footprint, and the overall cost of ownership. Many condition-based monitoring sensors are now available as connected IIoT solutions, allowing for remote monitoring and diagnostics of mobile equipment.

Maintaining the strategy

Figure 4: Bypass filtration system.

As you develop and implement a precision fluid contamination control strategy, it is extremely important to document it. Documenting the strategy and how to carry out the maintenance and inspection for each step helps create uniformity and consistency in the process. It provides the framework for work instructions to which team members can refer and ensures they are maintaining the strategy. Teams can then take the following steps to set the precision fluid contamination control strategy in place.

• Set the ISO 4406 target cleanliness levels.

• Prevent contamination from entering the hydraulic system.

• Remove contamination that may have entered the hydraulic system during operation.

• Visually assess the hydraulic fluid and overall system condition during operation and idle time.

• Monitor the hydraulic fluid in real time with condition-based monitoring.

Documenting a process associated with each of these steps improves the reliability of mobile equipment hydraulic systems, reduces unplanned downtime, and ultimately increases operational efficiency and throughput. Committing to a precision fluid contamination control strategy with proactive maintenance should improve the bottom line.

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The Unvarnished Truth

Contamination Control Makes Servo Valves Click Richard Trent, Regional Sales Manager, and Raymond Weaver, CFPHS, District Sales Manager, Hy-Pro Filtration

T

issue paper is manufactured by various companies across the globe by complex machines that use hydraulic systems. In most cases these systems contain servo valves. As most fluid power professionals are aware, servo valves have a low tolerance for contaminants and require the cleanest fluid of all hydraulic components. This is due to tight clearances between the various internal parts of the valve. Particles that may be too small to cause issues with most hydraulic components can cause servo valves to operate erratically, which leads to premature failure. Failures with these valves is costly in downtime and valve replacement and repair.

In the spring of 2018, a tissue mill experiencing weekly machine trips that resulted in downtime on one of their machines contacted Hy-Pro. The cause was attributed to issues within the hydraulic control system, which contained multiple servo control valves. Each trip led to hours of troubleshooting and sometimes valve replacement before the machine could be brought back online and into production. The mill was looking for a solution to the trips and valve failures, which were impeding operations and increasing production costs. Their prior efforts of implementing an offline electrostatic filtration system and replacing various components within the system had not produced the desired results.

At the first onsite meeting, we reviewed the root-cause failure analysis of the failed servo. The reports, which were supplied by the valve manufacturer, showed contamination as the root cause of valve failure. The reports also noted the presence of varnish. We also reviewed an oil analysis, which showed elevations in the membrane patch colorimetry (MPC) value and the ISO cleanliness codes. We also learned at this meeting that the hydraulic-fluid manufacturer had recommended that the system be converted from using AW32 to AM68 oil. Further, the oil manufacturer recommended flushing the system with a system cleaner prior to installing the new hydraulic oil to remove as much residual varnish from the system as possible.

After viewing the hydraulic system, the discussion turned toward contamination control. Reducing contamination within the system should result in a reduction of system failures and machine trips. The company wanted a total contamination control regime to achieve a lower operating ISO cleanliness code and also to deal with varnish.

The mill had installed an offline electrostatic filtration system onto the system sometime in the past to combat varnish. ASTM International uses ASTM.D02C.01 to define varnish, and ASTM D7843 covers MPC. The MPC test has become known as the varnish potential test. Essentially it involves diluting 50 ml of in-service oil with 50 ml of a nonpolar solvent. The dilution occurs after the sample has been heated to 150°F (65°C) for 24 hours and then aged at 70°F (21°C) for 68-76 hours. Once it is diluted, the fluid is drawn across a filter 10

OCTOBER 2021

patch, and filtered solvent is drawn across the patch to remove any residual oil. The patch is allowed to dry and then placed onto a sheet of aluminum foil along with a clean white patch. A device called a spectrophotometer then determines the delta E between the two patches, with the white patch being used to calibrate the spectrophotometer. The delta E values can range from 0 to > 100. The higher the delta E, the higher the potential for varnish to form.

Note that the results are not yes or no for varnish. We’ve seen systems with the same lubricant exude no evidence of varnish even though they had delta E values greater than systems with lower delta E values that were also experiencing varnish-related failures. It is our opinion that MPC should be held as low as possible, with the trend being constant as opposed to increasing over time.

Oxidation by-products In short, varnish is the result of oxidation by-products precipitating out of solution with the fluid itself. Lubricants and hydraulic fluids oxidize over time. Oxidation can be described as the loss of an electron in the presence of oxygen. Mineral-based lubricants and hydraulic fluids contain antioxidant additives (AO) to arrest oxidized molecules and decrease the rate of oxidation.

Other things that lead to increased oxidation include excessive heat as well as water and other contaminants.

As oxidation continues to occur, it creates more by-products. Eventually a point can be reached where there are more oxidation by-products present than the fluid can hold in solution. These oxidation by-products precipitate out of solution and begin to plate onto various metal surfaces. At this point varnish begins to form in the system. If the situation continues unchecked, it shortens the life of the components and the fluid itself.

Areas that generally collect varnish first are areas of low flow (reservoir), areas of tight clearances (servo valves), and cooler areas of the system (heat exchangers). Varnish has an interesting relationship with temperature. Fluids can maintain more oxidation by-products at higher temperatures versus lower temperatures. This explains why varnish appears where it does, as precipitation can more easily occur in these locations.

Varnish formation within hydraulic fluid is a broad and complicated subject. We discuss it in this article for simplicity and expediency, since varnish was a major factor in the machine trips and servo valve failures in the tissue mill’s hydraulic control system. We now look at varnish mitigation and the subsequent results at this mill.

We now know that varnish is the result of oxidation and that oxidation within mineral-based lubricants and hydraulic fluids accelerates at temperatures higher than 150°F (65°C). As water and other contaminants accelerate oxidation, a good first step is to keep the fluid clean, dry, and cool. Minimizing oxidation increases the time before a fluid becomes saturated with by-products.

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Varnish mitigation Even with a system operating under the clean-dry-cool parameters above, oxidation will occur. For that reason, varnish mitigation should be considered.

There are many types of varnish mitigation systems available. Offline electrostatic filtration was one of the first systems marketed to control varnish. There are multiple manufacturers of electrostatic filtration systems, and Hy-Pro is one of them. These types of systems have been applied to lubricants and hydraulic fluids for a couple of decades. Most of these, including Hy-Pro’s, incorporate a pump that produces flow through the skid. The fluid flows through filter housings installed with collector elements. High-voltage DC current is applied to metal plated within the collectors, and insoluble oxidation by-products are “collected” onto the plates. The drawback of electrostatic filtration units is that they can only remove insoluble oxidation by-products. This leaves the fluid saturated at the temperature at which the fluid is processed. At any point that the temperature decreases, insoluble by-products can precipitate out of solution, and varnish can form. We do not apply electrostatic filtration to mineral-based fluids for this reason.

Other forms of varnish mitigation systems include ion exchange or ioncharged bonding (ICB) resins. Our experience is that resins achieve the lowest MPC values of in-service fluids. We have been supplying offline systems using

1 micron in size when they precipitate out of solution. That is much smaller than typically mechanical filters can capture. Also, they are most often still in a liquid state at that point. Properly designed depth media provides a place to capture these insoluble by-products. To keep it simple, the by-products plate to the various fibers and stay within the media. Depth media mostly targets insoluble oxidation by-products, but our VTM has shown the ability to decrease acid, leading to the theory that it removes a small number of soluble by-products. VTM and other types of depth media can remove water as well.

Installing VTM After discussing these points with the mill, the company decided to install VTM onto its hydraulic system. Since the system already contained an offline filter cooling loop, the mill installed a larger filter housing within the loop using this media. After installation, MPC decreased from > 20 to 5.1, and the ISO cleanliness code was 16/13/9 on a sample taken May 22, 2019. Previous samples showed it as high as 21/20/17, with the lowest showing 19/17/12. In June 2019, the oil manufacturer’s recommended cleaning fluid was installed and the system operated for a couple of days. Samples taken on June 20, 2019, showed that MPC had increased to 10.1, indicating the cleaning fluid was doing what it was supposed to do. The June sample showed that ISO cleanliness had increased to 20/18/12.

Results of fluid tests before and after installing VTM DATE

MPC #

ISO CODE

4U

6U

14U

New from barrel

3.6

19/17/13

4904.27

1055.20

50.93

Upper Limit 16/14/11

>4m/ml

>6m/ml

>14m/ml

21/20/17

16304.00

5837.00

1084.00

Incumbant

24184

April 2018 from lab report

MEDIA

WATER PPM 136.78

5.22.2019

5.1

16/13/9

348.00

53.00

4.00

VTM Only

39

6.20.2019 during flush

10.9

20/18/12

8203.00

1422.00

38.00

VTM Only

68

7.25.2019

3.1

14/11/7

83.07

19.40

0.87

VTM and 6M

116.35

8.29.2019

5.2

16/13/9

411.13

50.53

3.00

VTM and 6M

68.05

10.24.2019

6.1

13/9/3

55.47

4.80

0.00

VTM and 6M

101.51

12.19.2019

6.7

12/9/5

22.60

3.93

0.20

VTM and 6M

78.32

1.30.2020

7.6

11/9/<3

12.93

2.67

0.00

VTM and 6M

78.08

10.29.20

5.4

11/9/<5

11.80

3.73

0.20

VTM and 6M

129.09

2.8.2021

5.4

11/9/<3

11.80

2.53

0.00

VTM and 6M

101.93

ICB resins for around 15 years and have achieved great results. These systems work by removing oxidation by-products that are still in solution with the fluid.

Once they are removed, the fluid regains solvency and can dissolve almost any existing insoluble oxidation by-products back into solution. From there the resin removes those. We prefer the use of resin technology for R&O fluids, like turbine and compressor oils as well as most synthetic fluids. Resin, however, is not recommended for all fluids, especially most antiwear (AW) hydraulic fluids. In most cases AW additives are polar, and most resins try to remove them while also removing oxidation by-products. There are some exceptions to this, but we recommend never applying a resin to AW oils unless the fluid is tested with the proposed resin. During this type of test, the AW additives in the new fluid are measured pre- and post-treatment to determine if AW additives are being removed.

A third type of varnish mitigation is the use of depth-filter media. This is not the same as typical glass-filter media that most filter manufacturers produce today. This style of depth media can be produced using different types of fibers, both natural and synthetic. Hy-Pro produces a depth media known as VTM. Other manufacturers also make this type of depth media.

This style of depth media does more than act as a mechanical filter, and that is an important distinction. As a rule, oxidation by-products are well below WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

A sample of the new fluid installed into the system after the flush showed ISO cleanliness as 19/17/13. The next sample, pulled on July 25, 2019, showed MPC at 3.1 and ISO cleanliness at 14/11/7. The most current sample from this system, pulled on Feb. 8, 2021, showed MPC at 5.4 and the ISO cleanliness at 11/9/<3.

From a contamination control point of view, these are great results. The operation results of the system and improved reliability of the hydraulic control system tell the story that matters the most. Since the installation of VTM media, the mill went from experiencing unscheduled downtime of four to six hours per week to a single occurrence as of Feb. 8, 2021. The company applied the same solutions to the other tissue machines onsite.

Arguably, contamination causes most hydraulic component failures.

We have reviewed articles that claim that as many as 75% of failures can be attributed to contamination. And it is widely accepted that servo valves have the lowest tolerance for contamination of all hydraulic components.

However, by understanding contamination and developing a clear solution for it, even servo valves can operate for long periods of time. First, work on clean, dry, and cool. Second, implement a control plan that covers all contaminants, including oxidation by-products. It will save money and valuable time.

•

OCTOBER 2021

11

I F P S U P D AT E

CELEBRATING 60 YEARS

Five Facts About IFPS Certification

1

IFPS CERTIFICATIONS ARE portable.

Example: Mary Smith, CFPHS. The certification designation goes with you wherever your career takes you.

2 3

WE’VE GOT YOUR PARTS RIGHT HERE. WE HAVE THE PARTS YOU NEED, AT THE RIGHT PRICE. Our inventory consists of both new OEM parts and our aftermarket brand Genuine Metaris parts, that support component brands like: Bosch, Continental, Denison, Eaton, Hitachi, Kawasaki, Linde, Oilgear, Parker, Rexroth, Staffa, Sundstrand and Vickers. Make

4 5

I FPS CERTIFICATIONS ARE highly recognized industry-wide.

I FPS CERTIFICATIONS ARE approved through the Skills Certification System, endorsed by the National Association of Manufacturers, as a stackable credential that can be earned in post-secondary education. For more information, visit www.themanufacturinginstitute.org.

I FPS IS APPROVED by the U.S. Department of Veterans Affairs to provide reimbursement for certification test fees.

If you are eligible, the VA reimburses you for taking IFPS certification tests.

I FPS CERTIFICATIONS ARE valid for five years, then you recertify. To recertify, you accrue a minimum number of professional development points during the five-year period and work in the fluid power industry for a minimum of three years.

Hydraulex your first call when you need replacement hydraulic parts for your hydraulic pumps and motors.

To learn more, give us a call or visit us at HYDRAULEX.COM

1.800.422.4279 sales@hydraulex.com

12

OCTOBER 2021

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I F P S U P D AT E

July 2021

CELEBRATING 60 YEARS

Newly Certified Professionals CONNECTOR & CONDUCTOR Joseph Hargenrader, Manitowoc Cranes Ryan Horst, Manitowoc Cranes David Houser, Manitowoc Cranes Nathan Loschiavo, Manitowoc Cranes Terry Nearhoof, Manitowoc Cranes HYDRAULIC SPECIALIST Greg Anderson, Vermeer Corporation Grant Fidler, Vermeer Corporation Jordan Flick, Vermeer Corporation Daniel Hofland, Vermeer Corporation Matthias Honermeier Joshua Irvin, Vermeer Corporation Jack Jaros, Vermeer Corporation Christopher Kownick, Vermeer Corporation Blake Krodinger, Vermeer Corporation Lucas Laverman, Vermeer Corporation Eduard Perekatov, Applied Industrial Technologies David Schad, Vermeer Corporation

PNEUMATIC SPECIALIST Daniel Bennett, American Cylinder Co. Terence Crowley, American Cylinder Co. Allysa Penamora, IMI Precision Engineering INDUSTRIAL HYDRAULIC MECHANIC Joshua Grisolia, The Boeing Company Grant Harvey, The Boeing Company Ryan Keller, The Boeing Company Dylan Longaker, The Boeing Company Jared Mitchell, The Boeing Company Grant Towns, The Boeing Company MOBILE HYDRAULIC MECHANIC Cole Adkins, Altec Industries Laramie Bales, Altec Industries Cameran Binette, Dagle Electric Construction Mike Brown, Connexus Energy Chris Carr, Altec Industries Jose Carrillo, American Electric Power Co. Hunter Chalifoux, Altec Industries

Matthew Christie Brandon Dean, Altec Industries Andrew Deel, AEP David Gallagher, Altec Industries Matthew Hall, Florida Power & Light Co. Matt Highfill, Canadian Valley Electric Coop Dakota Jenkins, Altec Industries Thomas Matuszak, Altec Industries Jesse Meier, Altec Industries Raul Morin, AEP Deavin Morrison, Altec Industries Mike O'Neal, Florida Power & Light Co. Michael O'Shea, Altec Industries Matt Roose, Florida Power & Light Co. Juan Soto, Altec Industries

YEARS

Custom Cylinders

Seals

Extensive Manufacturing and Repair in the USA

Standard Cylinders

Rotary Actuators

Swivel - Rotary Union

HOW BIG DO YOU WANT IT?

Spherical Bearings

63 Dixie Highway • Rossford, Ohio 43460 • www.hunger-hydraulics.com • +1.800.248.9232 WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

OCTOBER 2021

13

When the Pressure Is on,

Quality Makes the Difference

Metro Hydraulic Valves Mobile and Industrial Valves • • • •

Control Valves Selector Valves Lock Valves In-line Valves • Restrictor • Relief • Check

+1 (320)743.2276 | doering.com © 2021 Doering, Inc. All rights reserved.

Introducing!

9S SERIES INVESTMENT CAST SWIVELS The “9S” Series swivels represent one of the most complete range of sizes and configurations available to the 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.

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OCTOBER 2021

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I F P S U P D AT E

CELEBRATING 60 YEARS

Study Manual FAQs

»

A FREQUENTLY ASKED QUESTION IS, How can I get an IFPS Certification Study Manual?

Members can download study manuals for free. Others can purchase a download or print copy.

Of course, when you register for a certification test, you automatically receive the free download.

Study manuals are necessary when preparing for a certification test, but they also serve as an on-the-job reference material. For a copy, visit www.ifps.org/study-manuals.

The ULTIMATE resource for hydraulic, pneumatic, and motion control professionals

Fluid Power

Reference Handbook FIRST EDITION

"

This is a great

technical resource!

Head and shoulders above any other fluid power reference book available today!

"

— H. Sam Kaye, CFPSD, CFPMIP, CFPMMH, CFPMIH, CFPS Order by visiting www.ifps.org.

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OCTOBER 2021

15

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: November 2021 Tuesday 11/2 • Thursday 11/18 December 2021 Tuesday 12/7 • Thursday 12/16 January 2022 Tuesday 1/11 • Thursday 1/27 February 2022 Tuesday 2/9 • Thursday 2/24

ALABAMA Auburn, AL Birmingham, AL Calera, AL Decatur, AL Huntsville, AL Jacksonville, AL Mobile, AL Montgomery, AL Normal, AL Tuscaloosa, AL ALASKA Anchorage, AK Fairbanks, AK ARIZONA Flagstaff, AZ Glendale, AZ Mesa, AZ Phoenix, AZ Prescott, AZ Scottsdale, AZ Sierra Vista, AZ Tempe, AZ Thatcher, AZ Tucson, AZ Yuma, AZ ARKANSAS Bentonville, AR Hot Springs, AR Little Rock, AR CALIFORNIA Aptos, CA Arcata, CA Bakersfield, CA Dixon, CA Encinitas, CA Fresno, CA Irvine, CA Marysville, CA Riverside, CA Salinas, CA San Diego, CA San Jose, CA San Luis Obispo, CA Santa Ana, CA Santa Maria, CA Santa Rosa, CA Tustin, CA Yucaipa, CA COLORADO Aurora, CO Boulder, CO Springs, CO Denver, CO Durango, CO Ft. Collins, CO Greeley, CO Lakewood, CO Littleton, CO Pueblo, CO DELAWARE Dover, DE Georgetown, DE Newark, DE FLORIDA Avon Park, FL Boca Raton, FL Cocoa, FL Davie, FL Daytona Beach, FL Fort Pierce, FL Ft. Myers, FL Gainesville, FL Jacksonville, FL Miami Gardens, FL Milton, FL New Port Richey, FL Ocala, FL Orlando, FL Panama City, FL Pembroke Pines, FL Pensacola, FL Plant City, FL Riviera Beach, FL Sanford, FL

16

OCTOBER 2021

Tallahassee, FL Tampa, FL West Palm Beach, FL Wildwood, FL Winter Haven, FL GEORGIA Albany, GA Athens, GA Atlanta, GA Carrollton, GA Columbus, GA Dahlonega, GA Dublin, GA Dunwoody, GA Forest Park, GA Lawrenceville, GA Morrow, GA Oakwood, GA Savannah, GA Statesboro, GA Tifton, GA Valdosta, GA HAWAII Laie, HI IDAHO Boise, ID Coeur d ‘Alene, ID Idaho Falls, ID Lewiston, ID Moscow, ID Nampa, ID Rexburg, ID Twin Falls, ID ILLINOIS Carbondale, IL Carterville, IL Champaign, IL Decatur, IL Edwardsville, IL Glen Ellyn, IL Joliet, IL Malta, IL Normal, IL Peoria, IL Schaumburg, IL Springfield, IL University Park, IL INDIANA Bloomington, IN Columbus, IN Evansville, IN Fort Wayne, IN Gary, IN Indianapolis, IN Kokomo, IN Lafayette, IN Lawrenceburg, IN Madison, IN Muncie, IN New Albany, IN Richmond, IN Sellersburg, IN South Bend, IN Terre Haute, IN IOWA Ames, IA Cedar Rapids, IA Iowa City, IA Ottumwa, IA Sioux City, IA Waterloo, IA KANSAS Kansas City, KS Lawrence, KS Manhattan, KS Wichita, KS KENTUCKY Ashland, KY Bowling Green, KY Erlanger, KY Highland Heights, KY Louisville, KY Morehead, KY

LOUISIANA Bossier City, LA Lafayette, LA Monroe, LA Natchitoches, LA New Orleans, LA Shreveport, LA Thibodaux, LA MARYLAND Arnold, MD Bel Air, MD College Park, MD Frederick, MD Hagerstown, MD La Plata, MD Westminster, MD Woodlawn, MD Wye Mills, MD MASSACHUSETTS Boston, MA Bridgewater, MA Danvers, MA Haverhill, MA Holyoke, MA Shrewsbury, MA MICHIGAN Ann Arbor, MI Big Rapids, MI Chesterfield, MI Dearborn, MI Dowagiac, MI East Lansing, MI Flint, MI Grand Rapids, MI Kalamazoo, MI Lansing, MI Livonia, MI Mount Pleasant, MI Sault Ste. Marie, M Troy, MI University Center, MI Warren, MI MINNESOTA Alexandria, MN Brooklyn Park, MN Duluth, MN Eden Prairie, MN Granite Falls, MN Mankato, MN MISSISSIPPI Goodman, MS Jackson, MS Mississippi State, MS Raymond, MS University, MS MISSOURI Berkley, MO Cape Girardeau, MO Columbia, MO Cottleville, MO Joplin, MO Kansas City, MO Kirksville, MO Park Hills, MO Poplar Bluff, MO Rolla, MO Sedalia, MO Springfield, MO St. Joseph, MO St. Louis, MO Warrensburg, MO MONTANA Bozeman, MT Missoula, MT NEBRASKA Lincoln, NE North Platte, NE Omaha, NE NEVADA Henderson, NV Las Vegas, NV North Las Vegas, NV Winnemucca, NV

CELEBRATING 60 YEARS

NEW JERSEY Branchburg, NJ Cherry Hill, NJ Lincroft, NJ Sewell, NJ Toms River, NJ West Windsor, NJ NEW MEXICO Albuquerque, NM Clovis, NM Farmington, NM Portales, NM Santa Fe, NM NEW YORK Alfred, NY Brooklyn, NY Buffalo, NY Garden City, NY New York, NY Rochester, NY Syracuse, NY NORTH CAROLINA Apex, NC Asheville, NC Boone, NC Charlotte, NC China Grove, NC Durham, NC Fayetteville, NC Greenville, NC Jamestown, NC Misenheimer, NC Mount Airy, NC Pembroke, NC Raleigh, NC Wilmington, NC NORTH DAKOTA Bismarck, ND OHIO Akron, OH Cincinnati, OH Cleveland, OH Columbus, OH Fairfield, OH Findlay, OH Kirtland, OH Lima, OH Maumee, OH Newark, OH North Royalton, OH Rio Grande, OH Toledo, OH Warren, OH Youngstown, OH OKLAHOMA Altus, OK Bethany, OK Edmond, OK Norman, OK Oklahoma City, OK Tonkawa, OK Tulsa, OK OREGON Bend, OR Coos Bay, OR Eugene, OR Gresham, OR Klamath Falls, OR Medford, OR Oregon City, OR Portland, OR White City, OR PENNSYLVANIA Bloomsburg, PA Blue Bell, PA Gettysburg, PA Harrisburg, PA Lancaster, PA Newtown, PA Philadelphia, PA Pittsburgh, PA Wilkes-Barre, PA York, PA

SOUTH CAROLINA Beaufort, SC Charleston, SC Columbia, SC Conway, SC Graniteville, SC Greenville, SC Greenwood, SC Orangeburg, SC Rock Hill, SC Spartanburg, SC TENNESSEE Blountville, TN Clarksville, TN Collegedale, TN Gallatin, TN Johnson City, TN Knoxville, TN Memphis, TN Morristown, TN Murfreesboro, TN Nashville, TN TEXAS Abilene, TX Arlington, TX Austin, TX Beaumont, TX Brownsville, TX Commerce, TX Corpus Christi, TX Dallas, TX Denison, TX El Paso, TX Houston, TX Huntsville, TX Laredo, TX Lubbock, TX Lufkin, TX Mesquite, TX San Antonio, TX Victoria, TX Waxahachie, TX Weatherford, TX Wichita Falls, TX UTAH Cedar City, UT Kaysville, UT Logan, UT Ogden, UT Orem, UT Salt Lake City, UT VIRGINIA Daleville, VA Fredericksburg, VA Lynchburg, VA Manassas, VA Norfolk, VA Roanoke, VA Salem, VA Staunton, VA Suffolk, VA Virginia Beach, VA Wytheville, VA WASHINGTON Auburn, WA Bellingham, WA Bremerton, WA Ellensburg, WA Ephrata, WA Olympia, WA Pasco, WA Rockingham, WA Seattle, WA Shoreline, WA Spokane, WA WEST VIRGINIA Ona, WV WISCONSIN La Crosse, WI Milwaukee, WI Mukwonago, WI

WYOMING Casper, WY Laramie, WY Torrington, WY CANADA ALBERTA Calgary, AB Edmonton, AB Fort McMurray, AB Lethbridge, AB Lloydminster, AB Olds, AB Red Deer, AB BRITISH COLUMBIA Abbotsford, BC Burnaby, BC Castlegar, BC Delta, BC Kamloops, BC Nanaimo, BC Prince George, BC Richmond, BC Surrey, BC Vancouver, BC Victoria, BC MANITOBA Brandon, MB Winnipeg, MB NEW BRUNSWICK Bathurst, NB Moncton, NB NEWFOUNDLAND AND LABRADOR St. John’s, NL NOVA SCOTIA Halifax, NS ONTARIO Brockville, ON Hamilton, ON London, ON Milton, ON Mississauga, ON Niagara-on-the-Lake, ON North Bay, ON North York, ON Ottawa, ON Toronto, ON Welland, ON Windsor, ON QUEBEC Côte Saint-Luc, QB Montreal, QB SASKATCHEWAN Melfort, SK Moose Jaw, SK Nipawin, SK Prince Albert, SK Saskatoon, SK YUKON TERRITORY Whitehorse, YU UNITED KINGDOM Elgin, UK GHAZNI Kingdom of Bahrain, GHA Thomasville, GHA EGYPT Cairo, EG JORDAN Amman, JOR NEW ZEALAND Taradale, NZ

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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

Upcoming Workshops IFPS is offering two workshops on certifications for Accredited Instructor (AI) and Authorized Job Performance Proctor (AJPP).

THE WORKSHOPS TAKE PLACE OCT. 26-28 IN CHERRY HILL, NEW JERSEY. The AI workshop is a one- or two-day program to acquaint fluid power professionals with this IFPS certification and to assess their instructional abilities. The program does not teach instructor skills but rather measures them in the student. IFPS AIs have extensive backgrounds and instructional experience in the fluid power industry. In addition to their instructor accreditation, they are committed IFPS members and hold various IFPS certifications.

IFPS AJPPs are certified to proctor the mechanic, technician, and Connector and Conductor job performance (hands-on section) tests. An individual must hold the certification they plan to proctor and must be an IFPS member.

The registration deadline is Oct. 5. To register, call (856) 424-8998 or visit www.ifps.org.

CFPMEC (In Development) Mobile Electronic Controls CFPIEC (In Development) Industrial Electronic Controls

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OCTOBER 2021

17

COVER STORY

TAKE10MEASURES Tips For Sizing Rodless Pneumatic Actuators

By Andrew Zaske, Vice President, Sales and Marketing, Tolomatic Inc.

T

here are many important points to consider when sizing rodless pneumatic cylinders. Some are relatively simple procedures, such as knowing available air pressure and determining the proper working stroke and overall length. Others can be more complex, such as determining the effects of moment loads, dynamic loading, and breakaway pressure. Manufacturers’ sizing and selection calculations can make it easier to select the appropriate cylinder. Here are 10 tips to help make the most accurate selection.

1

Obtain an accurate air-pressure reading.

Overestimating or underestimating the available air pressure can cause a loss in actuator performance or possibly a complete malfunction. To obtain an accurate reading and build in safe engineering practices, check the air pressure with a gauge. For example, a plant may supply 100 psi of pressure. However, pressure can fluctuate as much as 10% at different locations in the plant due to variable demand cycles.

This means the actual available air pressure is only 90 psi.

A 5% to 10% fluctuation in air pressure is quite common and can make a big difference in selecting the proper cylinder for an application.

It is always best to factor in a 10% loss from the gauge air pressure.

2

In the illustration below, the nonworking (dead) space required by the mounting and carrier mechanisms is defined as 3.94 inches at each end of the actuator. In this case, the actuator requires 7.88 inches of total dead space. Add this dead space to the desired working stroke requirement to determine the overall actuator length. In this example, the actuator needs to have a working stroke of 16.12 inches. To determine the overall length, add the working stroke (distance of travel) and the total dead length: working stroke (16.12 inches) + total dead length (7.88 inches) = overall length (24 inches).

money and air consumption. On the other hand, undersizing a cylinder may save a few dollars, but it will not provide optimal application performance or the appropriate operational safety factors. For optimal performance, size the actuator based on load, force, and bending moment performance capacities with a safety margin factor.

To properly size a cylinder, you need to know these application requirements:

• Available air pressure • Magnitude of load • Orientation of load (location relative to cylinder carrier)

• Final velocity of mass attached to carrier

• Working stroke length • Cycle rate • Cycle time • Center of gravity of load in relation

to the cylinder’s load carrying device

• Orientation of the actuator

Calculate the actuator’s working stroke and overall length.

An actuator’s “dead length” is the portion of the actuator stroke that cannot be used due to the interference of the internal components and the room needed to physically come to the end of stroke. This dead length is determined by the manufacturer and should be indicated on the dimensional information for each actuator.

18

The actuator’s overall length is the sum of the distance of travel (working stroke) and the given dead length at each end of the actuator. Auxiliary carriers and other actuator options will also add to the actuator’s dead length. For example, for a cylinder with two carriers, add the total dead length, working stroke, and the distance between the center of carriers to determine the cylinder’s overall length. It is important to reference the dimensional information provided by the manufacturer when ordering options to properly determine if additional dead length is required.

OCTOBER 2021

3

Size the cylinder accurately.

When it comes to cylinder sizing, bigger is not necessarily better. Oversizing can cost more in

Once you know these factors, then determine the cylinder’s load (thrust) force capacity based on the indicated available air pressure. The WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

cylinder should perform within the specified capacity range. If the application requires performance at the maximum level for that cylinder, consider either a larger bore size or a different cylinder style with higher capabilities.

Moment Directions

The illustrations below, viewed from the top of the cylinder, show the effects of dynamic loading to the cylinder and its load carrying device.

This condition occurs at deceleration (end of stroke) and acceleration (beginning of stroke.)

After selecting the bore size, calculate the magnitude and orientation of the load. Often, a cylinder is selected based only on the force it can produce. If the actuator will also support a load, it is important to know the bending moment capacity of the cylinder’s bearing and load carrying system. This will determine if the cylinder is capable of performing consistently under the load requirements. Also, when determining the force requirements, consider dynamic moment loading, discussed in tip 5. Selecting the wrong cylinder can result in poor performance, reduced life, excessive component wear, and cylinder failure.

4

Know the effect of resulting moments (torques).

The position and size of the load on the cylinder determines the resulting bending moments applied to the cylinder itself. Even if a load is located on and directly over the center of the load carrying device, it will still be subjected to bending moments on acceleration. It is important to determine if the cylinder is capable of handling the resulting moments. For off-center or side loads, determine the distance from the center of mass of the load being carried to the center of the cylinder’s load carrying device and calculate the resulting bending moment. For example: Distance of center of mass of the load from the center of the cylinder’s load carrying device = 3 inches. Load being carried is 30 pounds. My = 3 inches x 30 lbs = 90 in-lbs.

5

Dynamic Loading

Calculate the effects of dynamic moment loading.

Unlike rod-style cylinders, many rodless cylinders must support the load during acceleration and deceleration at each end of stroke. When there are side or overhung loads, calculate the dynamic moments to determine which rodless cylinder is best equipped to handle the resulting forces.

6

Understand the importance between average and impact velocity.

Velocity calculations for all rodless cylinders must differentiate between average velocity and impact velocity. For example: Stroking a 24-inch actuator in 1 second yields an average velocity of 24 inches per second. To properly determine the inertial forces for cushioning, it is important to know the final or impact velocity.

A guideline for determining the final (impact) velocity is: 2 x the average velocity (2 x 24 in/sec = 48 in/sec impact velocity).

MX, MY, and MZ moments are created by loads applied at a distance from the respective X, Y, or Z axes. An example is an overhung load that is centered off to the side of the cylinder’s load carrying device. MX moments create a rotation around the X axis, and the red arrow indicates the direction of the resulting “roll” motion on the cylinder’s carrier and bearing system.

MY and MZ moments likewise create rotation around the respective Y and Z axes. The resulting “pitch” and “yaw” motions are shown by red arrows.

The farther away the load is from the center of the cylinder’s load carrying device, the larger the resulting moment.

Published bending moments are usually a maximum and assume only one type of moment is being applied. Some applications involve two or more of the moments described above. Evaluate each application and calculate per the manufacturer’s equation to determine if the cylinder is capable of the combined moment force.

In the first illustration, the ball represents an overhung side load exerting an MX moment on the cylinder’s carrier.

The second illustration shows what happens when the cylinder reaches one end of its stroke.

When the carrier stops, inertia keeps the load moving forward, creating a dynamic twisting moment (MZ) on the cylinder.

The same thing happens when the cylinder cycles to the other end of stroke. The resulting dynamic moment may exceed the rated capacity of the actuator. After repeated cycles, the actuator may not achieve its designed life expectations if not properly selected.

Shock absorbers (mounted on the cylinder) are normally used in such applications to help compensate for the inertial effects of dynamic loading. In addition, place a stopping device nearest to the center of gravity of the moving load. For more information on this topic, see tip 7.

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OCTOBER 2021

19

(Continued from page 19)

7

Calculate the cushion or shock absorber capacity.

Most rodless actuators are equipped with internal devices to help cushion the load at end of stroke. It is important to know the final or impact velocity to determine the cylinder’s cushioning capacities. In the graph on the right, the final velocity has been determined to be 50 inches per second, and the load being moved is 5 pounds. The intersection of these two points indicates that the level is within the cylinder’s cushion capacity, which is indicated by the yellow lines. Consideration now must be given to load position and the resulting moments exerted on the cylinder, (refer to static and dynamic moments in tips 4 and 5) to determine if shock absorbers or external load stopping devices are required.

In the illustration below, the cylinder is carrying a 10-pound load and traveling at a final velocity of 80 inches per second when coming in contact with the shock absorber located at the ends of the cylinder stroke. The load must be stopped within the shock absorber stroke of 0.50 inches. The Mz and equivalent force applied to the cylinder’s load carrying device need to be within the limits of the cylinder’s rating capacities.

If the final velocity cannot be accurately determined, consider using limit switches with valve deceleration circuits or shock absorbers.

8

Factor in the effects of motion lag due to breakaway, acceleration, and friction forces.

It is important to understand how other forces and losses affect the total force required to

produce the desired motion. The total force calculation considering all sources of forces and frictional losses is: Ft (total force) = Fa (acceleration force) + Ffr (forces due to friction) + Fbk (breakaway force) Breakaway force. Every rodless cylinder requires a certain amount of energy or force to move itself with no load attached. This is the breakaway force. When

reviewing the performance information for the cylinder, be sure that breakaway force is accounted for in the calculations. In pneumatic applications, it is best to have excess force available to achieve reasonable acceleration.

Acceleration force. The amount of force required to accelerate a mass is typically larger than the force required to keep the load in motion. When selecting an actuator, add the breakaway force of the cylinder and the frictional drag of the load to the acceleration force requirements.

Friction forces. Friction forces occur when two materials slide across each other’s surface. The level of friction present between the two materials is defined by a numeric value called the coefficient of friction (COF), which varies depending on the material, the surfaces with which it comes in contact, and the type of friction (sliding or rolling) being generated.

Engineering reference tables should be used to determine the COF for materials and surfaces used for specific applications.

For horizontal applications, to determine the force required to overcome the friction, multiply the mass (weight) of the load by the COF: Ffr (forces due to friction) = μ (coefficient of friction) x WL (weight of load)

20

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9

Size for vertical vs. horizontal applications.

There are additional force, load, and air considerations when a cylinder is mounted vertically in an application. A vertically mounted cylinder must also overcome the force of gravity before it can accelerate the load upward.

In addition, certain types of pneumatic rodless actuators may experience some degree of air leakage. If the actuator is required to hold a load vertically for any length of time, the amount of air leakage can affect how well that position can be maintained.

"When it comes to cylinder sizing, bigger is not necessarily better."

In certain circumstances, some other type of holding device (such as a brake) or external guidance system may be required to safely control the load. Vertical applications with externally guided loads still experience moment loads due to the effect of gravity. For example, a 50-pound load with a bracket arm 12 inches from the actuator’s load carrying device would be subjected to a 600 in-lbs moment load.

10

Know environmental conditions.

Extremely hot or cold temperatures, external abrasives, dirty or wet conditions, caustic fluids, and air quality are just a few of the environmental conditions that can affect cylinder life. The effects of friction wear (abrasive, pitting, adhesive, and corrosive) due to particulates or fluids coming in contact with the cylinder can cause premature wear, increased maintenance, and possible equipment failure.

Most manufacturers specify a cylinder’s performance based on normal operating conditions. If the cylinder is to be operated in adverse environmental situations, discuss the application with the manufacturer to determine if the cylinder is capable of delivering the expected performance.

Determining the right pneumatic rodless product can be an in-depth process because there are many different styles to consider.

But in many applications, the space-saving feature and integral load-bearing system of rodless cylinders make them an ideal choice for linear motion. Consulting with an experienced manufacturer improves the selection process. The result: long life and trouble-free cylinder performance.

•

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OCTOBER 2021

21

TEST YOUR SKILLS

SELECTING VACUUM PADS

V

acuum pads are primarily used for handling smooth surfaced material but can be used with textured or irregular shaped material as well. Because sheet glass and other products that have a smooth surface generally have few to no places for attaching mechanical hooks and grippers, vacuum pad technology enables the material to be efficiently and safely moved.

Because of the many applications for using vacuum pad lifting technology, and the many possibilities of surfaces and working environments encountered, vacuum pads come in various shapes, sizes, and materials to allow a wide selection range.

The principle behind vacuum pad technology is very simple. The area of the pad multiplied by the applied pressure results in a holding

force. The pressure within the pad is less than atmospheric (vacuum).

The differential pressure between atmospheric and the vacuum level within the pad is the effective pressure, against the area of the pad contacting the surface of the material, resulting in a force holding the material to the pad. The pad is attached by placing it against the surface and then drawing a vacuum. The force required to pull the cup away from the surface is proportional to the vacuum and size of the pad.

The higher the vacuum, or larger the vacuum pad, the stronger the pull force required to detach the vacuum pad.

If the vacuum is provided in units of negative pressure (-psi or -kPa) then the calculation is the standard formula for force. If the vacuum is provided in a different unit of measure, the simplest solution is to convert the units to the equivalent negative pressure first.

Torr (mm mercury)

psia, (lb/in2) Absolute

Inches Mercury Absolute

Inches Mercury Vacuum Gauge

kPa Absolute

760 700 600 500 400 300 200 100 50 1 0

14.7 13.5 11.6 9.7 7.7 5.8 3.9 1.93 0.97 0.01934 0

29.92 27.6 23.6 19.7 15.7 11.8 7.85 3.94 1.97 0.03937 0

0 2.32 6.32 10.22 14.22 18.12 22.07 25.98 27.95 29.88 29.92

101.4 93.5 79.9 66.7 53.2 40 26.6 13.3 6.7 0.13 0

Vacuum units of measure.

22

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Proper selection of vacuum pads is much more involved than the simple pressure times area calculations. The effective force used in the calculation must include the acceleration forces in all directions in addition to the weight of the workpiece. The interface between the vacuum pad and the workpiece is not a 100% seal. The accepted practice is to add a safety factor to the load based on the orientation and direction of movement. For applications that include only static holding, a safety factor of 2:1 is acceptable. Vertical lifting and horizontal movement (which are shear forces) should use a minimum safety factor of 4:1. If the vacuum pads are positioned horizontally with the workpiece positioned vertically, a minimum safety factor of 8:1 is recommended.

EXAMPLE 1

selection. Other considerations that should not be overlooked are nonmarking and antistatic requirements.

radius is 0.5 inches Area = 1.5 • 0.5 • π (3.14) Area = 2.36 inches Calculate the force of one vacuum pad: F = p • a = 10.87 • 2.36 = 25.65 lb. per pad.

Total force (required including safety factor) = 96 lb.

Number of pads = 96 lb. / 25.65 lb. per pad = 3.74 pads.

Number of pads required = 4.

EXAMPLE 2 What is the lifting capacity of a quantity of 10 vacuum pads, each with an effective diameter of 30 mm using a vacuum of -55 kPa? The recommended safety factor is 8:1.

The combined force for lifting and moving a workpiece is 24 pounds.

SOLUTION

The vacuum is 7.8 in-Hg absolute (200 torr).

Calculate the total area of the pads. Each pad = 302 • 0.7854 = 707 mm2.

The oval shaped pad has dimensions of 3 inches x 1 inch.

Using a minimum safety factor of 4:1, how many pads should be used?

Use atmospheric pressure of 14.7 psia.

SOLUTION Calculate pressure difference between atmospheric conditions and the vacuum: 1 in-Hg = 0.491 psi 7.8 • 0.491 = 3.83 psia Pressure differential = 14.7 – 3.83 = 10.87 psi differential.

Calculate the area of the vacuum pad. The area of an oval pad is found by multiplying the major radius by the minor radius then multiplying by pi (π): The oval pad has dimensions of 3 x 1 inch.

The major radius is 1.5 inches and the minor

Total area = 10 • 707 = 7,070 mm2.

Calculate the theoretical lifting force.

(55 • 7,070) / 1,000 = 388.85 N. Determine lifting capacity including safety factor. 388.85 / 8 = 48.61 N. The surface of the workpiece will also affect the quantity and profile of the vacuum pads that should be used. Multiple pads will distribute the force to prevent damage due to deflection. Multiple pads also provide an additional margin of safety in the event of the failure of one pad. Pads that have a bellows or oblong shape provide for a better sealing surface on rounded or uniquely shaped parts.

The surface of the workpiece will influence the type of material of the pad. Softer materials form a better seal to reduce the amount of leakage but are subject to more wear. Residue of the workpiece manufacturing process and temperature will also influence the material

Safety tip: Regular inspection of vacuum pads is necessary for continued safe performance.

Any damaged pad should be replaced immediately to maintain proper safety margin.

Using pivoting ball mounts at the interface between the vacuum pad and the tooling will improve the ability of the vacuum pad to be positioned perpendicular to an oddly shaped workpiece. Nonrotating mounts will ensure that oval shaped pads maintain proper orientation. Mounts with springs will permit greater positioning flexibility. An example would be a transfer line that removes product from a stack. As the stack height is reduced, the spring will take up the movement, rather than adding an actuator to sequentially lift the stack, or a complicated control that either monitors the height of the stack or the number of parts transferred, to reposition the height of the pad.

A vacuum check is a simple solution to ensure that a momentary loss of vacuum will not cause the part to drop. However, it may hinder the ability to release the vacuum once the process is completed. Additional circuitry may be required, including redundant systems applying vacuum from separate vacuum generators to multiple pads.

The actual application of the vacuum pad has many other unknowns that cannot be easily identified. Excessive dust or inconsistent surface finishes will affect the leakage, which will adversely impact the vacuum level. Before approving the final design, the fixture must be extensively tested with several different workpieces to ensure proper long-term operation.

•

TEST YOUR SKILLS 1. With a flat piece of sheet metal that weighs 100 lbs. and with atmospheric pressure at sea level – using 4 circular vacuum pads that each have a diameter of 4 in. What is the minimum required vacuum needed for static holding, with standard safety factor of 2:1, on each cup?

A. 10.2 in-Hg gauge.

B. 26 in-Hg absolute.

C. 8.1 in-Hg gauge.

D. 14.7 psia.

E. 700 torr.

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2. What is the equivalent pressure of 300 torr in kPa (a) absolute?

A. 40.0 kPa (a).

B. -45.3 kPa (a).

C. 56.0 kPa (a).

D. -56.0 kPa (a).

E. 238.7 kPa (a).

Solutions found on page 31.

OCTOBER 2021

23

Family Friction: Lubrication Management Grows Up Michael Cook, Fluid Power Technical Specialist, and Beth Figliulo, Segment Manager Fluid Power, Trelleborg Sealing Solutions erformance, efficiency, and longevity are qualities that matter in fluid power applications. They’re also things that an effective sealing and lubrication system safeguards. Such a system demands a fresh approach to lubrication management, one that looks at each element of the system as a complementary component of a unified whole. A team approach is the foundation of good lubrication management and, even in a field that is still very much in its infancy, it’s easy to see the long-term benefits.

P

Then and now From the invention of the wheel and the discovery that animal fat smeared on axles would ease movement through to the cutting-edge machines of today’s heavy industry, lubrication has been integral to the story of humanity’s innovation and development. The scientific discovery of friction; the rise of petroleum lubricants; and the advent of synthetic solid, semisolid, and liquid lubricants are all part of the story. Lubrication management is the latest advancement improving the performance of the machines that make the world turn.

Today lubrication and sealing are critical to the performance of the total machine. And it’s widely recognized that the fundamental challenges in sealing moving machine parts are establishing a good sealing system and ensuring long service life. Solving these inextricably linked challenges is crucial to effective application performance. However, sealing and lubrication are often overlooked by plant managers, whose maintenance budgets may be allocated elsewhere. But lack of effective lubrication is identified as the primary cause of premature machine bearing failure.

Lubrication management is more than simply choosing and applying a lubricant. It’s managing and adjusting the lubrication conditions of all elements within a sealing system, which reduces the load on each element and optimizes performance in terms of friction-wear lifetime. This holistic approach to machine maintenance focused on the friction points of the seals and bearings is necessary because the interfaces between surfaces in motion are constantly subjected to pressure and wear.

Given the complexity of today’s industrial machines, suitable lubrication management takes a strategic, problem-solving approach. Reducing unplanned costs and downtime while maintaining 24

OCTOBER 2021

the integrity of the sealing system requires assessment of potential issues before devising a solution.

The challenge The world is dynamic, and products are subject to failure. Energy continually shifts from one state to another while prevention of perpetual motion occurs by friction, wear, and resistance at the atomic level. In this physical universe, lubrication is one way to hold back the tide of entropy, which reduces the available energy to do mechanical work. Lubrication makes equipment run more smoothly, perform more efficiently, and last longer.

The battlefronts for lubrication are a machine’s seal contact areas, or friction points; effectively lubricating them can be the difference between costly repairs and smooth running.

The exponential growth of technology and the resulting demands of an “always on” world mean that today’s machinery is increasingly dynamic, more efficient, intricate, and precision engineered.

But this doesn’t mean machinery can break the laws of physics. Friction, wear, and pressure all pose threats to this machinery, potentially causing part failure, service downtime, and rising costs. And in applications in which seals play a critical safety and operational role, the challenge of friction and wear multiplies exponentially.

Friction is the great enemy, impacting hydraulic systems and seals in a variety of ways. When designing a lubrication management system, it’s important to consider many factors, including the following.

1. Pressure and speed. Smaller and lighter machines have led to an increase in the pressure and speed of hydraulic applications, pushing polyurethane materials to their sealing limits.

2. Coating of counter surfaces. Designers often do not consider the sealing system when selecting coatings, which can decrease the lifespan of both the seals and the machinery.

3. Rough surfaces. Tiny imperfections, embedded holes, uneven textures, and friction-creating characteristics in the interfacing surfaces of high-speed applications can abrade the seal as it passes.

4. Modifications and post-processing. Making seal modifications in isolation of the system overall to extend seal life and prevent wear can be costly.

The solution Applying lubricants to seals under pressure loads can extend the life of the seal and mitigate the effects of friction and wear. However, this is a simplistic view given the previously mentioned speed and pressure challenges of modern machinery, as well as the mandatory need for redundancy in critical industrial applications.

In fluid power and hydraulic sealing applications, best practices involve using primary and secondary seals in tandem. The primary seal does the grunt work, maintaining integrity for as long as possible; the secondary seal is a redundancy measure, ready to step in when needed.

Conventional seals have high contact pressure with the rod, meaning an adequate amount of oil fails to be in the contact zone of the primary seal and cannot go through to the second seal, which is left in a dry running situation, which leads to high friction and wear.

Though seemingly simple, a focused lubrication management approach can potentially revolutionize fluid power performance. Lubrication management balances the risk of lubricant leakage WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

to ensure the performance of the primary seal and the extended life of the secondary seal.

To facilitate lubrication management, new innovative seal designs incorporate rounded sealing edges to give a neutral or inverse contact pressure.

In this sealing arrangement, the primary seal still takes the pressure load in the hydraulic system, but it is lubricated much better and has an easier life in terms of friction and wear. That lowers contact pressure against the rod, which allows just enough lubricant to enter the hydraulic system to efficiently lubricate the piston rod, reducing friction and wear. The secondary seal is no longer dry running and operates under better conditions.

If a pressure buildup occurs, there is a ventilation function built into the seals.

Trelleborg Sealing Solutions has rigorously tested this type of lubrication management technology.

The testing included wear tests of a polytetrafluoroethylene (PTFE) sealing system against a laser-clad (an alternative to chrome) counter surface. Being soft and sensitive, it wears easily, and it is not an easy surface to seal against. In the tests, standard sealing configurations caused significant wear on the rod. However, the lubrication management technology showed virtually no wear on the rod or seals.

Friction tests for the PTFE system followed a standard procedure in which, on a test rig, the sealing system runs at a different velocity and pressure combination for 86,000 cycles and at temperatures of 30°C and 50°C (86°F and 122°F). The result showed a dramatic reduction in both constant and break-out friction along with a consequential wear reduction.

In the standard system, without lubrication management, loss of radial heights for the primary seal during the test period was between 5% and 6%. Using lubrication management, the wear was virtually halved to less than 3% percent reduction of the radial heights. Wear on the secondary seal for the standard system was around 6%. Lubrication management reduced the wear on the secondary seal even more than for the primary seal, to below 1%. This means lubrication management technology can significantly extend seal life for the whole system.

Trelleborg conducted similar tests on a polyurethane sealing system that yielded comparable results. In addition, we conducted a short-stroke endurance test that mimics pitch control cylinder applications in wind turbines. The stroke length was only 10 mm, so the primary seal never covered the same area as the secondary seal, making the lubrication conditions for the secondary seal very poor. The test ran at a velocity of just 4 mm per second, at constant pressure of 250 bar (3,626 psi) over 1 million double strokes.

After 1 million double strokes, both the primary and secondary seals were in good condition. The WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

wear on the counter surface was much more impressive. With standard systems, there are issues with run in of the secondary seals. After the endurance test, the sealing system based on lubrication management technology showed only slight discoloration where there was contact between the seal and countersurface, and the wear was zero.

The demands of the modern world place increased pressure on machinery to work reliably

for longer periods of time, while ongoing economic pressures fuel a never-ending quest for cost effectiveness. To meet these demands, it’s essential to keep things running smoothly, and lubrication management for sealing systems can help do this.

To develop effective sealing systems, it is important to work with an experienced sealing solutions partner.

•

TRELLEBORG SE ALING SOLUTIONS

Maximize the lifetime of your hydraulic systems

Effective sealing in demanding hydraulic applications requires seals and lubricant to work together. Trelleborg’s Lubrication Management technology transforms hydraulic sealing by adjusting lubrication conditions of all single sealing elements within a sealing system.

Find out more by visiting www.tss.trelleborg.com/accelerate or scanning the QR code.

OCTOBER 2021

25

ABSOLUTE ADVANTAGE Proportional Valves for Pressure Regulation

By John Kelly, Engineering Manager, Kelly Pneumatics

F

or decades, electronic pressure regulators (or IP transducers) have been a staple of pneumatic control systems. Some electronic pressure regulators still use solenoid valves, but this can cause various issues in pressure control applications.

Many of these issues can be solved by incorporating proportional valve technology as both flow inspiration (fill) and flow expiration (vent) for pressure control.

To better understand the advantages of proportional valve technology for pressure control, we need to consider the general properties of electronic pressure regulators and proportional-valve design.

Electronic pressure regulators have many advantages over mechanical regulators. A mechanical regulator maintains pressure downstream, most effectively with constant flow rates. However, downstream flow and pressure often fluctuate in most applications. Pumps and compressors deliver pulses, and the pressure fluctuates with demand. When a mechanical pressure regulator lacks accuracy or can’t respond fast enough, the result is uneven pressure output. This simple device might be good enough when accuracy isn’t as crucial. However, an electronic or digital pressure regulator delivers better accuracy and dynamic output pressure regulation by using a control signal and the feedback signal to create closed loop pressure control.

Electronic pressure regulators maintain a constant output pressure within a pressurized system even if there are fluctuations in the incoming pressure to the regulator. Mechanical pressure regulators are typically only adjustable by hand, limiting their usability in high-tech applications.

When using an electronic pressure regulator with a digital control system, the precise output pressure is controllable via slight adjustments to the control signal. An internal pressure transducer creates a true closed loop control device and offers a feedback voltage of the current output pressure. By reading this feedback signal from an electronic regulator, control systems can make real-time adjustments, greatly improving consistent pressure regulation in the most demanding applications.

26

OCTOBER 2021

Electronic pressure regulators are a big improvement over mechanical regulators; they are fairly simple and effective at allowing better control. They use a fill valve and a vent valve to maintain the outlet pressure at the desired set point. A small internal pressure sensor monitors the output pressure, and the digital controller adjusts the flow output of the internal valves to retain the required set point (i.e., closed loop control). That means that when you set the desired pressure, the regulator maintains this pressure even with changing flow rates through the system. The internal pressure transducer gives immediate feedback to adjust the flow of either the fill or vent valve so the output pressure remains static.

When the control signal increases, the internal proportional valve activates, increasing pressure into an internal pilot chamber. When this happens, more of the inlet pressure passes through the proportional fill valve and into the pilot chamber. The pressure in the pilot chamber grows and causes the upper surface of the diaphragm to operate.

Because of this, the air supply valve linked to the diaphragm opens, and a portion of the supply pressure becomes output pressure. This output pressure goes back to the control circuit using the pressure sensor. The fill valve continues to slightly adjust until the output pressure is equivalent to the desired set point of the control signal.

As we’ve shown, in standard electronic regulator design, using very accurate and fast fill and vent valves greatly affects

the overall pressure control characteristics. But how do proportional valves achieve this?

Proportional valves Traditional electronic pressure regulators typically employ a dual on/off valve design, with both an inlet and exhaust valve. Changes in pressure are controlled by cycling the on/off valves to open and close via pulse width modulation. Using pulse width modulation can be problematic for control systems for various reasons. Problems associated with using pulse width modulation of on/off valves and frequent valve cycling include a much shorter product life, product noise, control circuitry deadband, pressure oscillation, and inconsistent performance during dynamic output conditions.

Some pressure regulators incorporate an inlet proportional valve to compensate for these performance issues. However, these units typically use a single on/off solenoid exhaust valve to vent excess pressure and compensate for changing flow rates to the system. Typically, this is achieved with rapid valve cycling, so applications with dynamic output pressure rates are more susceptible to oscillation, as the exhaust valve must continually cycle at a rapid hertz to compensate for the dynamic pressure changes.

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The critical component of a Kelly Pneumatics electronic pressure regulator is the dual proportional valve design. One valve controls the inlet and the other the exhaust; each valve proportionally increases or decreases the output pressure, respectively.

The incorporation of two proportional valves avoids many problems associated with traditional on/off valve regulators. This is mostly due to the inherent design of the proportional valves that control pressure regulation. Each proportional valve uses a single armature design, which offers virtually frictionless performance. Outlet pressure/flow is acquired by proportionally moving the single valve armature away from the valve inlet orifice. The total travel distance of the valve armature is only thousands of an inch. A slight increase or decrease in the armature distance from the valve orifice results in variable outlet flow rates and pressures.

Conversely, on/off valves do not typically offer variable flow rates and use an armature with a single calibrated travel distance. The valve armature during the off state is completely closed against the valve seat, while during the on states it is completely opened against the valve housing.

On/off valve cycling can be can be problematic when considering the aforementioned use of pulse width modulation in other pressure control units that must cycle valves at a particular hertz, which can substantially lessen the life of the solenoid valves being cycled and subsequently the product itself. This is especially true of applications with consistent outlet flow or frequently changing output pressures to the system when valve cycling is more consistent. Therefore, in many applications, valve cycling can be constant for these products, severely limiting product life. In the Kelly Pneumatics electronic pressure regulator, however, the internal proportional valves need only change their respective armature distance to change the output pressure and flow of the pressure controller. For example, when an increase of flow occurs downstream, the inlet proportional valve immediately adjusts to compensate by slightly adjusting the internal valve armature distance in a single movement. Additionally, during steady states, the proportional valves maintain the valve armature distance, with no wear to the valves themselves.

Using on/off valves for either fill or vent valves in pressure controllers can lead to problematic WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

deadband in control systems. Due to the pulse width modulation of cycling on/off valves, this can cause rates of deadband in the control range at certain set points because the control algorithm may not calculate a small enough adjustment when cycling the fill and vent valves at particular frequencies. Since the proportional valves are able to finely adjust the internal armature height, fine tuning the output pressure is much more effective, preventing deadband for most set points and fine tune adjustments to the output pressure.

Using proportional valves also avoids the occasional pressure oscillations caused by pulse width modulated on/off valves. In static output conditions, the constant valve cycling of on/off valves can cause sudden missteps in pressure output with varying downstream flow conditions. These oscillations can affect applications that require constant output pressures over long periods between set point adjustment.

In comparison, any changes in downstream flow conditions are quickly adjusted for by the proportional fill and vent valves, since the internal valve armatures only need to make slight adjustment to the immediate armature position (oftentimes only thousands of an inch).

Another issue with using pulse width modulation is the audible sound generated by rapidly operating on/off valves. Many of these older designs with on/off valves for filling and venting must operate the valves at an oscillation in hundreds of cycles a minute, meaning that the valves have to fully close and open, generating audible clicking.

In contrast, since the proportional valve design does not require oscillation, there is no sound generated by the valves when changing flow outputs for either filling or venting.

This is because the proportional armatures are adjusted through a single armature movement, rather than requiring a full on/off cycle.

Proportional valves for both fill and vent valves in electronic regulators offer huge improvements for pressure control. From extended product life, to improved accuracy and quieter operation, proportional valves in electronic regulators make all the difference.

•

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Superlok Zero Leak 20 x 3262 - cap 11.3 Technology Tube Fittings

Boom arch hose cap kit EX3600, EX5600, EX8000 The new Festo configuration tool for valve units makes process automation easier than Superlok tube fittings are equipped with CONTAMINATION CONTROL ever. Generate the perfect flow control solution industry’s built-in gap gauge.

Routine and scheduled maintenance of hydraulic systems are vital to getting the mostthe out of your Hitachionly Mining Excavator.

While for your application minutes and choose maintenance plays the largest role inwithin the prevention of unnecessary machine downtime, it can installation, also expose thethe hydraulic system During compression to high levels decreasingincluding component longevity. The importance of contamination control is sometimes fromofacontamination wide rangerapidly of options, nut is simply tightened until the gap overlooked when performing maintenance due to incorrect practices being used. safety, speed, hygiene, corrosion resistance— gauge rings pop off. This is the point of perfect THE FLANGELOCK and more. ™ TOOL AND CIRCUIT BLANKING CAPS compression and seal, which provides an added level BOOMARCHCAP3262

The FlangeLock™ tool and caps are the ultimate contamination control tools for protecting your hydraulic system. The FlangeLock™ ofbesafety and accuracy companies worldwide. allows for the simple sealing of open hydraulic flanges without tools while the caps can bolted in place of a flangefor connection. tools and capsends leaks that are Easy on, easy off, they offer a leak-proof solution to hydraulic systems and environmental cleanliness.patented FlangeLock™innovation Superlok’s stop the mess.

caused by improper tightening procedures.

HITACHI MAKING CONTAMINATION CONTROL EASY

Superlokworld.com Hitachi have packaged FlangeLock™ tool and caps specifically for Hitachi mining excavators. The Hitachi customised kits make sureFesto.us no matter which component routine maintenance is being performed on, you will always have the exact Visit for more information. number of FlangeLocks™* and caps to help reduce contamination. *Note: FlangeLocks™ are not to be used under pressure

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 Hydraulex Reman Rexroth A10V Units Available MONEY • No more messy plastic caps SAVE • The

ultimate contamination control tool Just a heads-up! We've lowered prices on all of our Hydraulex LABOR • One

hand installation Reman™ brand Rexroth A10V series units. This lower pricing affects SAVE • Eliminate

hydraulic oil spills & clean up all unit displacement sizes including 18, 28, 45, 60, 71, 100 and OIL • Quick

installation & ease of usage 140 that we stock and remanufacture. And don't forget, they’re • Safe

for personnel & environment remanufactured in the USA and backed with an industry-best two • Industry

acclaimed year (24-month) warranty.

For more information, call 203-861-9400 or email For more information, call us at sales@flangelock.com.

1-800-422-4279 or www.flangelock.com visit www.hydraulex.com WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

OCTOBER 2021

29

SPECIAL AD SECTION

Dual-Action, HighPressure DCHP20-3 Cartridge Hand Pump Doering’s DCHP20-3 hand pump delivers 2.0 in.3 flow per stroke at pressures up to 3,000 psi. Double the performance of single-stage pumps, DCHP20-3 moves fluid on up and down strokes.

Heavy duty and compact, it operates in all orientations and the handle socket rotates 360°. Perfect for primary, backup and emergency power applications, DCHP20-3 mounts in a standard C20-3 cavity.

Valve + Actuator: Compact Automated On/Off Valve The VA Series is a compact, pneumatic on-off coaxial valve, available in 3/8” to 2”. Nickel plated brass body, Buna-N, Viton or EPDM seals make it ideal for hydraulic, pneumatic and vacuum control.

Operating life has been tested to well over 1,000,000 cycles.

Visit our unique online Valve Configurator to build, view, price or order your valve package easily and quickly. https://assuredautomation.com/VA/ 800-899-0553 • sales@assuredautomation.com

+1 320.743.2276 | Doering.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.

Telescopic Cylinders NEW xtremeDBm® With the release of the NEW xtremeDBm®, your system just got smarter, stronger, and smaller.

With the addition of the 6-port family members— including a robust CAN Splitter—to the current 10-port xtremeDB lineup, all the same great CANBUS and control capabilities become even more modular and customizable at half the size of the original models. www.datapanel.com/xtremeDBm

30

OCTOBER 2021

With a rapidly changing situation in the world markets, we noticed a shift in a demand for telescopic cylinders.

Magister Hydraulics offers a variety of telescopic cylinder designs including standard and custom cylinders.

The most popular industries for Magister telescopic cylinders are waste management, dump trailer and dump truck manufacturers.

Call us for details 973-344-5313

WWW.FLUIDPOWERJOURNAL.COM • WWW.IFPS.ORG

SPECIAL AD SECTION

Bringing Valves Closer Together! iPolymer’s new Manifold product line combines our High Purity components into one compact, easy to install, integrated solution. Our Manifolds are carefully designed to reduce leak points and pressure drops. They come fully tested and ready to install. iPolymer Manifolds are ideal for semiconductor, life science and general chemical applications. LET US HELP YOU FIND YOUR NEXT HIGH PURITY SOLUTION!

ADVERTISER INDEX Company..................................................Page Almo Manifold & Tool Co.................................. 31 Andrew Black & Associates....................... 13, 27 Assured Automation......................................... 30 Clippard Instrument Lab Inc..28, 31, Back Cover CFC-Solar............................................................. 9 Data Panel Corp.......................................... 21, 30 Doering Company....................................... 14, 31 Festo Corp......................... Inside Front Cover, 29

www.ipolymer.com 949-458-3731 info@ipolymer.com

Flange Lock................................................... 3, 29 Fluidyne Fluid Power................................... 28, 31

Contact us to showcase your products and services in the Product Spotlight.

This special section is a high-profile area offering product-specific advertising.

Visit fluidpowerjournal.com for more information or to view our media guide.

Fluid Power Inc.................................................... 9 Hydraulex............................................... 15, 29, 31 Hydraulics, Inc............................................. 14, 28

CL ASSIFIEDS

International Polymer Solutions................... 3, 31

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

HIGH FLOW PROPORTIONAL FLOW CONTROL

WANTED SURPLUS

Main Manufacturing Products Inc............. 28, 31 MAKO Products................................................. 29 MP Filtri USA Inc................................................. 9 Peninsular Cylinder Co. Inc.............................. 12 Wilkes & McLean Ltd.................................. 14, 29 Trelleborg Sealing Solutions............................ 25

10 & 15 mm Electronic Valves

• 16MM to 50mm • Standard ISO 7368 and DIN 24342 cavity • High performance 5,000 psi • On board amplifier • 0-10 volt command

almomanifold.com

Magister Hydraulics...................................... 1, 30

Compact, quick, powerful!

Technical Support

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

Pumps · Motors · Valves · Servo/Proportional

Large Inventory Standard, High Flow, Latching & ISO Series

Email, call or fax with a list of your Surplus.

We’ll provide you with a price offer!

1-800-422-4279 | 586-949-4240 Fax: 586-949-5302 | surplus@hydraulex.com

IN STOCK FROM 25MM TO 80MM MANY COVERS IN STOCK • Pressure, Flow, Directional • Large Flow 90° Valves

almomanifold.com

WWW.IFPS.ORG • WWW.FLUIDPOWERJOURNAL.COM

• Single DIN blocks • Active Valves • Monitored Poppets

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

877-245-6247 The correct answers to Test Your Skills on page 23 are 1.c and 2.a.

OCTOBER 2021

31

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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02  NO. Not interested. /

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Please Type or Print Clearly: First Name

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 Check here if you would like to keep your name, address, phone and fax numbers confidential, and not released to third parties The address above is my:  Home Address  Business Address Which edition would you like to receive?  Print  Digital  Both (View a sample of our PAPERLESS digital edition at www.fluidpowerjournal.com) 1. Do you specify, select or influence the purchase of components & systems, on new or existing machinery?

If yes, which technologies? (check all that apply) 05  Hydraulic 06  Pneumatic 07  Vacuum 08  Electronic Controls

03  Yes

04  No.

09  None of These

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

D  100-249

E  250-499

F  500-999

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

G  1000+

60  End User of Fluid Power Products

MY COMPANY SHOULD BE ADVERTISING IN OR SUBMIT AN ARTICLE TO THE FLUID POWER JOURNAL. PLEASE CONTACT THIS PERSON: NAME:______________________________________ TITLE:_______________________________________

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TARGETED DISPLAY ADVERTISING (PROGRAMMATIC) Digital ads that will help you reach your customers and also increase your audience reach on desktops, laptops, tablets and smartphones.

Reach the right customers with geo-targeting If they’ve been to your website, searched for your products and services, or they’re reading content relevant to what you offer, we’ll help get your message in front of them today! Plus all campaigns are geo-targeted, ensuring that we only share your ad with potential customers in your defined service area.

Deliver your ad and leave an impression on potential customers who have visited your website, but then left.

Deliver your ad to potential customers who are searching for your products and services online.

Win the attention of consumers searching for your competitors online AND send your ad to them when they are physically visiting your competitors.

Boost your print ad response in Fluid Power Journal by up to 400%.

Deliver your ad to consumers who are reading online content that includes your type of product or service.

Strengthen your brand and target more potential customers to search for your business online.

Drive more relevant traffic to your website.

Targeting people based on their specific online behavior.

Deliver your ad to potential customers within your service area who use laptops, desktops, tablets, and mobile devices.

Have visitors stay longer and view more pages on your website.

DISPLAY ADVERTISING Programmatic Division

Please contact your Fluid Power Journal account representative for packages and rates.

Precision

Control Solutions Designing efficient systems involves much more than simply understanding a few basic principles. There is a true art to balancing the specific requirements of an application in order to achieve the desired goals in the best possible way. Help us understand the unique needs of your application and together, we’ll develop something that surpasses what any of us could have done alone.

Contact your distributor to learn more, or visit clippard.com to request a free catalog and capabilities brochure.

• • • •

Electronic Valves Proportional Valves Isolation Valves Precision Regulators

• • • •

Toggle & Stem Valves Needle Valves Electronic Pressure Controllers Pneumatic Assemblies

• • • •

Special Manifold Designs Pneumatic Circuit Design Cylinders Fittings, Hose & Tubing

877-245-6247 CINCINNATI • BRUSSELS • SHANGHAI