Fluid Power Journal September/October 2010

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contents September/October 2010

•

Volume 17

•

Issue 8

Features

9 10 12 20 28

IFPS Certification Success Story:

Norgren, Inc.

Fluid Power Industry

Remembers Ted Munroe as Entrepreneur, Friend

Maximum Recommended Compressed Air Flow in Pipes

By John F. Berninger, Parker Hannifin

29 30 32 Diagnosing and Correcting

Dieseling Seal Failure

By Hercules Sealing Products

Something is missing: using alternative energy

By Dan Helgerson, Cascade Steel Rolling Mills, Inc.

The Pressure-Flow conundrum

By Brendan Casey

Intelligent Hydraulics

Make Plastic Sheet Extrusion Faster, Simpler, and Safer— and Smarter

Press Loading with Vacuum

By Daniel Pascoe, General Manager, Vacuforce, Inc.

By Bosch Rexroth Corporation

departments

4 6 7 7 8 14 19 22 33 39 39

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

Official Publication of The International Fluid Power Society

Request more information at www.fluidpowerjournal.com

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

Fluid Power:

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

Past, Present, and Future As the International Fluid Power Society (IFPS) celebrates its 50th anniversary, there have been many accomplishments in the fluid power industry. For the fluid power industry to survive, however, we must focus on the future and the next generation of fluid power personnel (engineers, technicians, and mechanics).

We must also place an emphasis on the working relationships between the fluid power industry and electrical interfacing, which will control all the machining global processes. Looking in the past, it can be noted that there have been many great accomplishments in system designs, installations, applications, and operation of hydraulically and pneumatically powered equipment. The fluid power professionals created and set-up the base line of processes that are currently being used by OEMs, fluid control suppliers, and end-users throughout the manufacturing world.

We need to move progressively into the future.

The next step is to bring a newer and often times younger generation into the world of fluid power.

The future between the end-users, OEMs, and fluid power control suppliers must place an emphasis on the commutations regarding the products being used to ensure environmental awareness and fluid power system consumption of both energy savings and the elimination of the standard “Rules of Thumb.” This will lead to the reduction of leakage issues and the measured improvements of system designs. The industry needs to begin setting their sights on issues of reduction of all fluid power component sizing and calculations for precise flow rates, pressure drops, Cv rate, friction losses, and straight threads with “O-rings” in the porting. Energy savings must also be a factor in reducing the cost of the system and pneumatic system leakage and focusing on the facility pneumatic air consumption. Applications of hydraulic systems must place more emphasis on the system’s design, power unit sizing, heat generation, hp losses, tubing as the heat sinks, smaller components, and more mobile components to be used in the manufacturing processes. More emphasis should be placed on using the correct filtration and contamination control that will be driven per the applications.

These are just some of the issues the future needs to address. 3-D modeling programs will continue to get even better to aid in the design of components and systems. Use of programs like fuzzy logic and 4 | September/October 2010

2010 Board of Directors

other think-tank processes will help lead the industry into the 21st century, as well as better international standards with more input from all sectors.

Integrating fluid power systems into overall machine safety and risk assessments will lead to accurate sizing of components and systems. Safety controller technologies and new safety standards, like ISO 13849, help to apply the appropriate system components for the desired task to be performed, improving safety for personnel and machinery at reduced costs. For example, safe slow speeds can include hydraulic and pneumatic motions, as well as electrical servo movement.

Fluid power education is a must. For those entering into the world of hydraulics or pneumatics, whether engineering, sales, maintenance, or operation, they have the opportunity to be trained and/or certified. We need educational institutions and industry programs that will provide those opportunities.

The IFPS certifications are a living process that will help to meet the manufacturers’ and personnel demands, but other types of certifications will be needed and will play a major role with the next generation of fluid power personnel. Colleges with either a two-year or four-year degree program must and shall have more related curriculum both theoretical and hands-on to meet the needs of all personnel.

Standalone Bachelor of Science, Master degrees, and Doctorate programs must be forthcoming. The National Fluid Power Association (NFPA) shall continue to work to provide better International Standards (ISO) that will help the fluid power community, OEMs, and end-users of the world to meet the demands set forth by the global manufacturing.

In conclusion, real-world manufacturing applications of fluid power are still the best commodities to use. Great strides have been made and better accountability is coming in the future with the marriage of Electricity (Brains) and Fluid Power (Brawn) to make manufacturing industrial equipment more efficient.

Here’s wishing another 50 more successful years of education and certification to the IFPS. James Simpson, CFPS, CFPMM, CFPAI, Nusim Associates, Fluid Power Consultant and Vice President of IFPS Education

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

Directors-at-Large

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

Honorary Directors

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

IFPS Staff

Donna Pollander, Executive Director Sue Tesauro, Certification Manager Adele Kayser, Communications Manager Sue Dyson, Membership Coordinator Connie Graham, Certification Coordinator Diane McMahon, Certification Coordinator Beth Borodziuk, Administrative Assistant Nick Pollander, Certification Assistant Diane McMahon, Bookkeeper Fluid Power Journal (ISSN# 1073-7898) is the official publication of the International Fluid Power Society published bi-monthly with four supplemental issues, including a Systems Integrator Directory, Off Highway Suppliers Directory, Tech Directory, and Manufacturers Directory, by Innovative Designs & Publishing, Inc., 3245 Freemansburg Avenue, Palmer, PA 18045-7118. All Rights Reserved. Reproduction in whole or in part of any material in this publication is acceptable with credit.

Publishers assume no liability for any information published. We reserve the right to accept or reject all advertising material and will not guarantee the return or safety of unsolicited art, photographs or manuscripts. POSTMASTER: Please send Address Corrections to Fluid Power Journal, PO Box 2548, Orlando, FL 32802-9830

www.ifps.org | www.fluidpowerjournal.com

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C elebrating 50Years

The International Fluid Power Society

IFPS Time Capsule

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

1990: “Train the Trainer” Program is Developed for Fluid Power Examination

The Certification Committee followed the standard format for examination development, which included job responsibilities, task inventory, performance standards, test questions (written and hands-on), test validation, certification tests, and training programs. Training, not normally part of certification test development, was added after it was found that too many mechanics did not have sufficient background to pass the Mechanic examination.

In the summer of 1990, the examination was unofficially released. The next six months were spent developing the “Train the Trainer” program for certified instructors and seminars for the mechanic.

The “Train The Trainer” program resulted in establishing five schools to certify instructors and indoctrinate them in the program. These schools and initial staff included Greg Gordon at Ohio State University, James A. Sullivan at Southern Illinois University, Mac Ferguson at Bessemer State Technical College, Robert Williams at Spokane Community College, and Ernie Parker at Hennepin Technical College.

The Society’s Board of Directors in 1990 voted to raise the status of chairman of certification and Ray Hanley became the first vice president of certification. This training program became an essential tool to identify and upgrade qualified personnel with improved safety, economics, quality services, and a host of other benefits resulting from a well-structured, supported certification program.

Historical information for this column was obtained from Fluid Power – The Hidden Giant, John J. Pippenger, P.E. (Oklahoma: Amalgam Publishing Co., 1992).

6 | September/October 2010

Original CFPAI class at Ohio State University Wooster.

(Photo provided courtesy of James Simpson)

“In 1990, I was hired into my first industrially related job by a major industrial hydraulic component and systems manufacturer. As part of that employment opportunity, I was expected to attain a certification through the then Fluid Power Society at a level commensurate with my job. In doing so, I became a member of the Society and became certified at several different levels.

Over the last 20 years, many things have changed: We are now known as the International Fluid Power Society and have expanded certifications. I have also had the opportunity to meet and befriend many of the fine individuals who make up our industry. Even if I had not become involved at the Board level of the Society, my career in fluid power would have been strengthened.”

- Rickey L. Rodeffer (CFPMT, CFPS, CFPMIH, CFPAI), 2010 IFPS President

www.ifps.org | www.fluidpowerjournal.com

AllAboutAir Calculating Cv for Pneumatic Applications Cv is a dimensionless number that indicates the amount of compressed air that will flow through a product, plumbing, or system. Cv is most commonly used to indicate flow through pneumatic valves.

For your reference, a Cv of 1 will flow 30 scfm with 90 psig applied pressure and 10 psid pressure drop or Delta P (Dp).

When the flow, Q SCFM, and operating pressure, P1 PSIG, are known, the Cv can be readily determined from common formulas.

When starting with a FORCE, TORQUE, VELOCITY requirement, some basic physics will determine the flow rate, pressure, and allowable pressure drop. Allow a minimum of 25% extra for friction, and pressure in motion will be P2 PSIG (=P1-Dp).

PLEASE NOTE: Working with Cv formulas, the greatest Delta P for the sake of the formula is 47% x P1. The lowest P2 pressure is 53% x P1. For example, with P1 at 100 psig, if the flow is to atmosphere (P2 is theoretically 0 PSIG), use 47 psig for Dp and 53 psig for P2.

ProductReview High-Flow Cartridge Filters

Rosedale Products, Inc. The High Flow line of horizontally mounted filter vessels contains 1 to 18 large surface area pleated cartridges in 40- or 60-inch lengths. The line has flow rates up to 400 gallons per minute for each element in select applications. The preferential flow path is insideout, ensuring that the collecting solids stay inside the filter cartridges as they are removed. The units are rated at 150-psi ASME code design. www.rosedaleproducts.com Continued on page 27

Ë

Proposed NFPA Standard T3.21.3 Ref T = 528 R (68 F) G = Specific Gravity = 1 for air

+ 14.7) Qscfm = 22.5 Cv ΔP (P2 TG Make T Constant Qscfm = .979 Cv Cv = .0444 Qscfm

ΔP (P2 + 14.7) TG /

ΔP (P2 + 14.7)

Make T Constant Cv = 1.022 Qscfm / ΔP (P2 + 14.7) FOR EXAMPLE Areain (.7854 Bore Dia.D ) x Stroke, L" = Vol Vin3 2

2

Compression Factor (Cfscf/ft3) = (P1 + 14.7) / 14.7 V x Cf / 1728in3/ft3 = SCF SCF x 60 / tsec = Q SCFM Cv = 1.022 Qscfm / ΔP (P2 + 14.7) Personal Favorite Q scfm = .00186 D2 x L x (P1 + 14.7) / tsec Thomas W. Kreher, CFPPT | Applied Pneumatic Controls, Inc. | OIL SMOKE® www.ifps.org | www.fluidpowerjournal.com www.applied-pneumatic.com

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September/October 2010 | 7

MathTeasers

with Professor P.V. Btfsplk

This Issue

New Problem: Pneumatic Accumulator What precharge pressure is needed when 4.45-gallon of oil is needed from a 10-gallon accumulator?

Given:

P2 = 3000-psi

T1 = 700°F

Previous Problem: Relief Valve

T2 = 1250°F (From July/August 2010 Issue)

Please compute the horsepower loss across a relief valve if it is set for 1000 psi and returns all its flow back to the reservoir from a 20-gpm fixed displacement pump.

Solution:

HP = gpm x psi / 1714 Hp = 20 gpm x 1000 psi /1714 Loss across relief valve is 11.668-Hp

Illustration: John Spisak

Winner: Richard Throop CFPAI, CFPAJPP, CFPS, CFPMM, CFPMT Michigan Fluid Circuit Design Fenton, MI

Correction:

Answered Correctly Ernie Parker CFPAI, CFPMM, CFPMT, CFPS, CFPCC Hennepin Technical College Eden Prairie, MN

In the July/August issue, the answer to the Expansion Tank problem was incorrect. The final answer should be 17.225-psig.

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

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

David Petersen CFPHS Brand Hydraulics Omaha, NE

Parker Cook CFPHS, Parker Hannifin Corporation Wickliffe, OH

Tri Nguyen CFPS Plymouth, MN

Jeffrey Greene CFPHS, CFPMHM The Raymond Corporation Greene, NY

Hp = 20,000/1714 = 11.668

Pat Galagan Mukwonago, WI John Guerrant CFPS, Berendsen Fluid Power Charlotte, NC Philip Lane CFPS, Vermeer Corporation Pella, IA

Arick Kaschalk CFPHS B.W. Rogers, Co. Macedonia, OH Joe Herder CFPS, Hennepin Technical College Eden Prairie, MN Harold Lawson CFPPS, Air, Inc. Franklin, MA

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

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Certification Success Story

Norgren, Inc.

Norgren, Inc. started as a small entrepreneurial company founded by Carl A. Norgren in the early 1920s in Littleton, Co. It is now an international company with 6,000 employees and total system capability with manufacturing plants located in the United States, Mexico, Brazil, United Kingdom, Germany, Spain, Czech Republic, Switzerland, and China.

One of the key breakthroughs in the early years of the company was a technical sales call made to Detroit in 1927. While meeting with engineers of a major auto manufacturer, Mr. Norgren sketched a system designed to solve the maintenance and lubrication problems the auto manufacturer was having with its air tools and equipment. This rough drawing became an ingenious reality resulting in the first in-line lubricator and paved the road of innovation in pneumatic fluid power components:

The company’s foundation was the technical application of pneumatic filters, regulators, and lubricators.

Today, it continues its use of Engineering Advantage to develop new, innovative products meeting the specifications of its international customer base.

Norgren’s aim is to become an integral part of its customer’s business, not just as a supplier but also a valued partner, driven by its customer’s objectives.

The current Norgren leadership views the improvement of technical pneumatic application skills as a job requirement, in both product engineering and sales disciplines, to build its presence in the fluid power industry. Norgren has supported the International Fluid Power Society through frequent certification programs, as well as through encouraging its employees to be active participants in the IFPS, FPEF, and FIRST. When the IFPS decided to split up the Fluid Power Specialist into Hydraulic Specialist and Pneumatic Specialist, and then developed a Pneumatic Technician certification, Norgren, Inc. participated in the original beta testing for both of these certification programs.

In the most recent round of pneumatic reviews, Norgren successfully applied for an education grant, offered in the State of Colorado for Colorado residents. The Manufacturing Extension Partnership (MEP) and the National Institute of Standards and Technology (NIST) grant help subsidize the three weeks of certification review, IFPS membership, and certification tests. Norgren is currently investigating grant availability in the five other states where it has plant locations.

Doug Morrill, CFPPS, the Americas training manager, is responsible for coordinating technical skills development and enhancement through the International Fluid Power Society’s pneumatic certification programs. Morrill worked with the IFPS staff to organize Pneumatic Specialist and Technician certification reviews, tests, and job performance tests. With the help of Michael Joannides, IFPS Hydraulic and Pneumatic Grand Slam and Accredited Instructor (AI), and retired faculty member from Henry Ford Community College’s fluid power program, and Clayton Fryer, IFPS Pneumatic Grand Slam, Accredited Instructor (AI), and Past President of the IFPS, retired from Norgren, Inc., the company successfully completed multiple Pneumatic Specialist and Pneumatic Technician reviews and tests.

At Norgren, 19 out of 20 candidates passed the Pneumatic Specialist test. Incredibly, Norgren’s application engineering group is 100% certified! With a new round of certification reviews being planned, Norgren’s product engineering and sales groups in the Americas will have nearly 75% of its employees completing certification reviews. This engineering and sales group coordination is seen as a major factor, in Engineering Advantage, to shorten the product development cycle, improve understanding of customer needs and wants, and identify total cost of ownership.

According to Fryer, the more technically oriented the product development and sales team, the better will be the new product outcomes. “The IFPS certification program is deemed as an investment in Norgren, Inc. employees and the Engineering Advantage model at Norgren, Inc.,” he said.

In addition to the product engineering, application engineering, and direct sales departments, Norgren is encouraging employees in the manufacturing, tooling, and maintenance departments to pursue IFPS Pneumatic certifications. According to Fryer, Norgren will be adding IFPS certifications in future employee career plans and objectives.

“Certification attainment is considered part of a technical career path at Norgren,” he said.

For more information, visit http://norgren.com/usa.

Norgren's Certified Employees Todd Ables PS Brian Himes Freddy Ayala PS Roger Hoffman Brent Borchardt PS Steven Lewis Robert Buck PS Stephen McConnell Edward Day PS Phillip McElroy Randy DeForge PT Jeffrey Meredith Mark Dennis PS Jacob Miller Bradlee Dittmer PS Harry Milton Mark Gallegos PT Tina Mohr Steve Haugen PS Douglas Morrill www.ifps.org | www.fluidpowerjournal.com

PS PT PS PS PS PT PT PS PT PS

Cody Mouret Mary Mowery Stephen Nagy Tom Nguyen Keith Percin Mark Pevoteaux Joseph Quinn Brian Roberts Robert Robertson Craig Rupp

PS PS PS PS PS PS PS PS PS PT

Barry Shockley PS Dennis Sims PS Charles Stack PS Jonathan Steigerwald PS Jeffrey Stephens PT Christopher Toohey PS Mark Vogt PT Charles Werdehoff PS Request more information at www.fluidpowerjournal.com

September/October 2010 | 9

Fluid Power Industry

Remembers Ted Munroe as Entrepreneur, Friend

T

he fluid power industry lost a professional entrepreneur and friend with the passing of James Edward “Ted” Munroe, who died on May 27, 2010. Munroe, known for his many accomplishments and passionate interests, started Paul-Munroe Hydraulics, Inc. (PMH), a successful distribution and manufacturing company that dominated the west coast fluid power market during the 1950’s/60’s/70’s and early 80’s. Through Ted’s initiative, PMH was the publisher of the first five editions of the Fluid Power Designers’ “Lighting Reference Handbook” that has become an industry standard reference and is available from IFPS. In 1952, after working for several years at Fluor Corp., Ted Munroe, together with William G. “Bill” Paul, Jr., a friend from Stanford, decided to start a business as a manufacturer’s representative and distributor of hydraulic and pneumatic equipment (now fluid power). R.W. “Bob” Mapel, also a friend from Stanford and Fluor, joined them a few months later and became an early partner in the company.

According to Mapel, when the business started, the three men faced several challenges, including lack of inventory and extended delivery times of components, some as long as 16 weeks. The three men persevered, however, steadfast in their mission, and it paid off. The company reinvested its earnings into inventory and manufacturing equipment, and grew to over 450 employees with eight offices in California, their primary marketing area.

“We represented manufacturers of the major components that are required in most hydraulic systems, and early on we recognized the need to insure quality by having the ability to fabricate, assemble, and test complete systems,” said Mapel.

“Our largest inventory was the complete offering of Vickers (now Eaton) pumps and valves—at the time, the largest manufacturer of hydraulic equipment in the U.S.” As the firm grew, Bill Paul assumed the distribution sales and administra-

tive responsibilities while Munroe, as chief sales engineer, was responsible for the sales for customers who wanted complete systems. Bob Mapel assumed total responsibility for engineering and manufacturing. The opportunities in the Systems area were more wide-ranging than just California and Ted took advantage of it, seeking those opportunities wherever they existed.

Some of Ted’s and PMH projects: PMH supplied actuating systems for all the work platforms in the Vertical Assembly Building at what was then known as Cape Canaveral (Cape Kennedy), which at the time was the largest missile assembly building in the world. In other parts of the space industry, the company supplied hydraulic operating systems to actuate the silo access doors in all the Minuteman Silos in the US. Many systems

Left: Robert W. Mapel, James E. Munroe, and William G. Paul, Jr., founders of Paul-Munroe Hydraulics, Inc. Bottom: The first building of Paul-Munroe Hydraulics, Inc.

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were supplied to Vandenberg AFB in California, notably a hydraulic drive system to move a mobile service tower that was equivalent in height to a 23-story building.

In the marine market, PMH provided anchor windless mechanisms as well as explosion proof valves on all the tankers bringing oil south from the Alaska pipeline. Also, PMH provided the operating system for the giant doors for ships that allowed trucks to deliver directly to the inside of the ship.

When a giant wind tunnel-jet engine test facility constructed for Aeropropulsion Systems at Arnold AFB in Tennessee was fully operational, it drew 600,000 hp of power from the Tennessee Valley Authority (TVA). PMH provided a 17,000 hp system that included sixty (60) 250 hp motors, and according to Mapel, this 17,000 hp system did nothing but shift valves in the complex!

Many test benches were built for the aircraft companies in California, including a device for United Airlines that predicted failures in an aircraft system so that preventative maintenance could be scheduled on the basis of need instead of at specified intervals. The company also supplied the operating system for the first AeroBridge, the telescoping walkway that allows passengers at the airport to embark directly from terminal into the aircraft.

Most notably, in Detroit, Munroe secured a contract at General Motors to build a 3600-hp central system for their Structures Testing Laboratory. The catch was that the supplier would have to build (in the winter) the 3000 sq. ft. building that housed the system under a parking lot. Munroe retained an architect and a contractor and when the project was completed, it was one of the more profitable contracts the company ever had. Subsequently, Ted sold similar systems to Ford and Chrysler (but without the building).

In the nuclear industry, Munroe developed a hydraulic snubbing device that allowed the steam generators (main boilers) in a nuclear power plant to move slowly with thermal expansion but lock up in the event of an earthquake or pipe rupture.

Through Ted’s efforts with Westinghouse, PMH snubbers were installed in many nuclear power plants in the U.S. as well as in France, Germany, and South Korea.

By the early 1980s, PMH sales had grown to over $50M, over 450 employees, 8 California sales and service branches, 1 central warehouse, and the PaulMunroe Engineering and manufacturing facility in Orange, Calif. Paul-Munroe Engineering consisted of the Energy Products division (Nuclear), Defense/ Marine division, and Systems/Controls division and Petroleum/Power division.

Mapel remembers, “Ted was a good engineer who had a great ability to seek out opportunities and fashion a product that fit the customers’ needs. He was an imaginative and fierce competitor who didn’t like to lose an order, but he liked people. Often his customers became personal friends.”

The three PMH founders/owners decided to retire in 1983, and the business was sold to a venture capitalist who had served on the PMH Board of Directors.

Subsequently, the business was split up and the distribution business was sold to Berendsen Fluid Power; the Nuclear Division of PMH was purchased by a group of the division’s senior management and continued under the name Enertech. Today, thanks to Ted’s vision of the worldwide growth of nuclear power generation, Enertech is a successful business unit of Curtiss-Wright’s Nuclear Group. After Paul-Munroe was sold in 1983, Ted found that he was too active to completely retire and worked with Berendsen and Enertech for another 17 years. Ted, as well as Bill Paul and Bob Mapel, were career mentors to many of their employees, some who are still active in the fluid power industry today.

In addition to Ted Munroe’s many professional accomplishments, he was a family man, a veteran, and a competitive sportsman. Ted loved and was proud of his children and 13 grandchildren. At Stanford, Ted captained the swim team and was a Pacific Coast Conference swimming champion. He spent three years as a second lieutenant and platoon leader in the U.S Army in the European theater during World War II, returning after the War to Stanford to complete his Masters in Industrial Engineering. He married Shirley Stephens in 1950, and they had three daughters and a son during a wonderful 17-year marriage. A few years after Shirley's death, Ted was blessed to marry Dorothy Rempel in 1969, and they spent 41 happy years together. As a competitive sailor for nearly 80 years, Ted served as the 1938 Commodore of the Balboa Island Yacht Club and as the 1973 Commodore of the Newport Harbor Yacht Club. He was proudly patriotic, a gentleman, a competitor, a leader, an innovator, a teacher, a mentor, and a friend to many.

Special thanks to the following individuals who contributed information to this article: R.W. “Bob” Mapel, Paul-Munroe Hydraulics; Arlene F. Corkhill, Curtiss-Wright Flow Control Company (a former Paul-Munroe employee and a staff assistant to Ted Munroe); and Bob Kraft, CFPE, CFPS, Kraft Fluid Systems, Inc. (After college and the Navy, Paul-Munroe was Bob's first employer in 1965, and he worked for Ted.)

Lightweight Composite

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www.ifps.org | www.fluidpowerjournal.com

September/October 2010 | 11

Compressed Air Flow in Pipes Maximum Recommended

By John F. Berninger, Parker Hannifin

T

ables of pressure drops for various flows and inlet pressures have been published1 but have not provided any recommendations for applications. This article describes a maximum recommendation for compressed air flow rates in pipes based on a percentage of inlet pressure loss for a length of pipe. An equation is developed to determine the recommended maximum flow rate, and two quick reference graphs are provided. The graphs are based on certain assumptions, but the equation can be used for those applications outside of the assumptions.

Development of the equation Consider the differential form of Euler’s equation (including the friction term): where Rhyd = di/4 for pipes

(2)

From the definition of mass flow: and From the equation of state, mass density can be expressed as:

(3) (4)

Substituting these, and rearranging terms, equation (5) is obtained for integration:

(5)

Which results in:

(6)

The logarithm term is negligible compared to the friction term and can be disregarded.

Now, consider pressure loss at the end of a pipe length to be a percentage (η) of the inlet pressure.

(7) Then: (p1 – p2) = η p1 1

12 | September/October 2010

and

(1)

The ”z” term is zero for horizontal pipes and negligible for many applications of vertical pipes.

The basic relationship for frictional stress of a fluid in a pipe is

For this analysis, it is desirable to use volumetric flow rates, expressed at standard atmospheric conditions. Therefore, convert the mass flow using the perfect gas law:

(8)

Substituting all of these into equation (6) gives the final equation:

(9)

Terms: Q0 = recommended volumetric flow rate at standard conditions (SCFM) p1 = inlet pressure (psia = psig + 14.7) p0 = atmospheric pressure (14.7 psia) To = atmospheric temperature (528 ºR) T = inlet temperature (ºR = ºF + 460 ) R = gas constant for air (53.3 ft.#f /#m ºR) g = conversion factor for units (32.2 #m ft./#f sec2) di = inside diameter of pipe (ft.) f = pipe friction factor (dimensionless) L = pipe length (ft.)

The friction factor will vary with the Reynolds number, and requires the assumption of a roughness value (e). The reference cited earlier describes that the value of e = 0.0015 ft. is a generally accepted value for clean commercial steel or wrought iron pipes. The friction factor (ƒ) is then determined from the Colebrook equation, which is written in the form below:

(10)

New Compressed Air and Gas Data; edited by Charles W. Gibbs, 1971; published by Ingersoll-Rand. www.ifps.org | www.fluidpowerjournal.com

Since the friction factor cannot be solved directly, an Excel chart is set-up to determine the several factors as shown by blocks of cells:

η

η

Max.Recommended Recommended Flow Flow in 100 Max. 100 ft. ft. Pipe PipeLength Length 1000

η

2" pipe

1 1/2 pipe 1" pipe

The Reynolds number is determined from:

Max. Flow --scfm scfm Max. Flow

100

Each block is set-up for a different diameter (a1, a2, a3), with each e/di ratio (0.0015/a1; 0.0015/a2; 0.0015/a3), and each with an assumed percentage of pressure loss (c1, c2, c3). Inlet pressures are assigned for each row of the block (p11, p12, etc.). Using a Moody diagram, select a trial friction factor associated with the e/di ratio. Calculate the resulting flow rate (Equation 9) and Reynolds numbers in each cell of the Excel sheet. Then calculate the X value from the Colebrook equation in the last cell. If the number is not close to the value 1.14, change the friction factor in the first cell (for the same inlet pressure). The Excel cells will automatically recalculate flow rate, Reynolds number, and X value.

Continue this process until the X value is close to 1.14. Then proceed to the next row and repeat the process for the next pressure level. Perform these calculations for each block of pipe diameters all at a fixed length.

1 1/4 pipe

1/2 pipe

3/4 pipe 3/8 pipe 1/4 pipe

10 1/8 pipe

1

0.1 0

20

40

60

80

100

120

140

160

Inlet Pressure Inlet Pressure --psig psig

Biographical Information:

(11)

μ = 0.039 x 10-5 #f sec./ft.2 for air at 68 ºF By substituting constants, this can be reduced to the following simple equation for air:

(12) Whenever any of the equations are used, it is very important to check units to be sure the process results in units as described in the Terms section above. Be especially careful between the units of #f (pounds force) and #m (pounds mass).

The following two charts are calculated from equation (9), using the assumptions listed below: A. Flow temperature = 68 °F = 528 ºR B. Pipe diameter = nominal for ASTM A-106, schedule 40 pipe but in units of ft.

C. Horizontally oriented pipe. (Some cases of vertical pipe.)

D. Friction factor calculated from Colebrook Eq. using e = 0.0015 ft.

E. Pressure loss over the pipe length is a percentage of the inlet pressure as follows:

John Berninger is the retired global engineering manager for pneumatic products at Parker Hannifin Corp. He continues to participate in industrial standards development in the NFPA and ISO. He is currently chair of ISO TC 131, Fluid Power and convenor of the ISO working group for air valves. He also serves as an independent expert witness in product liability cases and patent infringement cases. He can be reached at: jberninger@parker.com.

SA E" A NO " D W OU IN BL ST E P OC UM K PS

η The results are that the Reynolds numbers are all above 4,000. Therefore all flow is turbulent.

Max. Recommended Recommended Flow Flow in in 10 10 ft. ft. Pipe Max. Pipe Length Length 10000 2" pipe

1 1/2 pipe

Max. scfm Max. Flow Flow --scfm

1000

1 1/4 pipe 1" pipe 1/2 pipe

3/4 pipe 3/8 pipe

100 1/4 pipe

1/8 pipe

10

1 0

20

40

60

80

100

120

140

160

Inlet psig Inlet Pressure Pressure --psig Request more information at www.fluidpowerjournal.com

www.ifps.org | www.fluidpowerjournal.com

September/October 2010 | 13

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ProductSpotlight | filtration, fluids, & seals Seal Kits Replacement seal kits for the repair or re-manufacturing of all makes and types of hydraulic and pneumatic cylinders including Caterpillar®, John Deere®, Komatsu®, Ford®, Bobcat®, Parker®, Miller®, Hydroline®, Leibherr® and many more.

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Hercules offers a complete line of Tie-Rod and Welded cylinders. Designed for a variety of equipment, the cylinders feature iron piston, iron gland with drilled oil passages, honed steel tube, high-tensile, hard-chrome plated-rod, iron end mounts, female clevises with pins and clips. Tube Seal: O-ring, Rod Seal: Deep polypak with B lip design; metal canned wiper. Piston Seal: (Crown seal or u-seals). Bore sizes start at 1-1/2 to 5 inches and strokes begin at 4-48 inches. All are in stock and ready for delivery! Call for special pricing on larger quantities.

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Hydraulic And Pneumatic Replacement Seals Hercules offers over 35,000 hydraulic and pneumatic inch and metric seals to meet your mobile and industrial cylinder repair needs. Product line includes: O-rings, rod seals, u-seals, wipers, backup rings, buffer seals, oil seals, piston rings, t-seals, wear rings, and vee packing for most fluid power applications including agriculture, automotive, heavy construction, material handling manufacturing, mining, logging, fluid handling and refuse. Hercules offers the largest in stock inventory, ready for next day delivery.

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Industrial Cylinder Seal Kits Hercules Sealing Products features industrial cylinder seal kits for main brand kits such as Atlas, Hydroline, Miller, Ortman, Parker, Royal, Sheffer and Thomkins Johnson. Rod seal kits can be ordered separately from piston seal kits. Also available are commonly found industrial cylinder cast iron and bronze guide bearings.

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Same Day Seals On Demand Hercules is proud to announce a new feature to our Seals On Demand program, Same Day Seals On Demand. This Same Day service offers a limited selection of custom manufactured seals in only one day, GUARANTEED. • Ships Same Day - Guaranteed!

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Retaining Adapters Inserta® 4-Bolt Retaining Adapters and Connectors provide an excellent means to retain and terminate a series of flange type modular components. They are ideally used with the Inserta® family of flange type ball valves, check valves, and modular fittings. The Adapter and Connector may be used together to sandwich modular components into an inline assembly, or the Adapter may be used alone to mount modular components onto a manifold surface.

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Self-Sealing Swivel Fitting Swivel Fittings alleviate the problem of tube alignment and rotation commonly found when using fixed barb fittings. The unique design, Patent #4,496,204, allows for 360° rotation and incorporates captured double o-ring seals to prevent leakage.

Nylon or Polypropylene fittings are available; Buna-N, Ethylene Propylene, Silicone, and Viton o-rings are available.

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The adapters are available in Code 61 and Code 62 sizes from ½" to 3", with the outlet port of the same or one reducing size. Adapters that permit conversion between Code 61 and Code 62 patterns are also available.

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8901-D Series Control Grip Cyber-Tech, Inc introduces our new 8901-D Series control grip.

Made from Die cast aluminum, this control grip will withstand today’s industrial market needs.

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• Nine trigger solutions ranging from a Single Triggers to a deadman Lever.

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• Custom option available.

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LockstackTM D03 Isolation System Inserta® Products introduces the LockstackTM D03 isolation system for use with D03 stack assemblies. The system consists of four stacking fasteners and a retaining module. The stacking fasteners are available in various lengths to accommodate a variety of component heights, and eliminate the need to size and cut thread stock. When assembled, the retaining module engages the stacking fasteners to resist loosening. This provides for stack and seal integrity during disassembly of the directional control valve or other components above.

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Cyber-Tech, Inc. 1.800.621.8754 www.cyber-tech.net 15

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ProductSpotlight | filtration, fluids, & seals H6 Heavy Duty Cylinder The Yates Industries H6 Heavy Duty Cylinder is rated for 3000 PSI and features 1½ to 20” bores standard, 22 different mounting options, is JIC-NFPA interchangeable, and can be customized with nearly limitless combinations of rod ends, cushions, couplers, seals, and ports – all backed by our legendary warranty and repair capabilities.

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The OILMISER™ Color Coding System, is a value added service that takes the uncertainty out of filter element selection.

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Turn Key Hydraulic Data Acquisition Solution From Webster Instruments

TORQTITE Adjustable Torque Wrenches

The C2000 is a complete instrumentation, display, logging, storage and reporting solution for hydraulic repair & rebuilding companies.

The system allows the operator to easily produce a traceable test certificate with graph. Scalable up to 64 inputs including flow, pressure, temperature, speed, contamination, torque or other analog inputs.

Flaretite’s new adjustable open-end torque wrenches allow all tube and hose ends to be precisely tightened to their correct torque recommendations. These new wrenches fill a void across all industries where fitting connections are used. Developed to compliment Flaretite’s patented flared seals for 30, 37, and 45 degree flared fittings, these new wrenches are used by quality conscious mechanics in hydraulics, pneumatics, pharmaceutical, chemical, medical and environmental industries.

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Torqtite wrench benefits: • Adjustable torque settings from 10 - 420 Nm (8 – 310 lb-ft) • Adjustable Hex size (jaw opening) from 7/16" thru 3" • Low profile, reversible, spanner design • Precision quality design with +/- 4% accuracy • Supplied with torque rating tables for most common fittings For more information contact: Flaretite Inc. Fenton, MI, USA • Ph: 810-750-4140 www.flaretite.com

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

Honor Gear Pumps Corp. of Taiwan, with U.S. warehouse in Houston, Texas, is pleased to announce the immediate availability of their 2DG series, double pumps. The aluminum body pump, employs cast iron covers for best performance under extreme conditions, and comes standard with viton seals. Displacements from 1.31 to .30 cu.in./rev. can serve many requirements, with working pressures up to 3000psi.

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Cleanline Portable FA 016/ FAPC 016 ARGO-HYTOS offers Cleanline portable an innovative fluid management solution.

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MODULAR STACK VALVES...D03...D05

Power Valve U.S.A. represents, as factory warehouse and sales office, a Taiwan manufacturer of D03, D05, D08, and their Modular stack valves product line. With inventory in the Houston warehouse, all products are competitively priced, and machine tool quality.

In fact the parent company, Tai Huei Oil Industry Co., Ltd. has been selling valves for over 25 years to the machine tool industry in Taiwan. All standard AC and DC voltages are available, and all standard spool configurations are in stock. Special spools are available. Pressures to 5000psi and flows from 16gpm (D03) to 132gpm (D08) are standard. With inventory on the shelf and very competitive pricing, we invite your inquiry.

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YOULI HYDRAULIC DIRECTIONAL CONTROL VALVES Pneumatic Operator option…..now available: Youli directional control valves, rated to 4600PSI, monoblock or sectional styles, are now available with pneumatic operators, in nominal flow ratings from 12GPM to 37GPM. Electrical operators are also available. Youli quality is based on 25 years of industrial hydraulic valve manufacturing for the machine tool business in Taiwan. A quality product line with a major commitment to inventory in Houston, Texas, and offered at competitive prices, is our growing reputation.

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

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Special Advertising Section • Request more information on Product Spotlight advertisers at www.fluidpowerjournal.com

ProductSpotlight | filtration, fluids, & seals Fast Simplified Cylinder Ordering Peninsular’s model HP, MH and LM cylinder Configurators accessible through Peninsular’s website at www.Peninsularcylinders.com make cylinder ordering easier because customers answer questions from drop down menus eliminating the need for confusing cylinder catalogs and complex engineering data. “Helpful hints” answer all user questions that may arise. A solid model and corresponding part number appear once configured. Instant solid model and 2D flatline drawings with dimensions may be instantly downloaded and instant quote requests included.

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Peninsular Cylinder Co. Inc. Toll Free: 800-526-7968 | Phone: 586-775-7211 Fax: (586) 775-4545

BSPP, BSPT, ISO 6149 Hydraulic Flanges & Couplings MAIN Manufacturing Products, Inc. now stocks SAE, JIS, DIN, and ISO flanges and couplings with metric ports. METRIC TUBE & PIPE sizes in socket weld and butt weld are also available.

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18 | September/October 2010

www.ifps.org | www.fluidpowerjournal.com

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

FigureItOut

New Problem: Stainless Plate Mill Straightener System A stainless steel rolling mill upgraded their “Plate Straightener” machine. The old hydraulic system was 40 to 50 years old with old manual valves and was overdue for an upgrade.

The original circuit consisted of three sets of top rolls with a cylinder pressing down on each end. There were also three sets of fixed Set @ 9000 PSI rolls on the bottom.

Each cylinder had a pilot to open (10,000psi rated) check valve on each port with an Enerpac relief in the cap end set for 9,000 A B psi. Each cylinder was controlled with a T P manual three-position shear-type, four-way, rotary directional valve with all ports blocked in the center position.

Set @ The operator would 2000 PSI adjust the position of M each roll by individually advancing one cylinder at a time watching its digital type position readout. Once it was Typical roll cylinder circuit positioned, he would 2 required per roll

Previous Problem: Varnish Build-Up (from the Manufacturers Directory 2010 issue) A customer requested our help in finding the cause of excessive varnish build-up on pilot pressure filters used in several Rexroth servo valves.

Our inspection of the hydraulic circuit drawings showed the overall systems were well protected with pressure, return, and component filters. These filters had good beta ratio numbers, high-quality manufacture, and more than adequate cooling capacity.

A site visit was made expecting to find excessive oil temperatures or a past history of periods where the systems overheated. The excessive varnish seemed to be concentrated between the component filters and the servo valves with the servo valve pilot filter clogging up and affecting the servo performance.

On the day of inspection, the system temperature was in the 100°F to 105° F temperature range--far below temperatures that cause oil varnishing. Inspection of computer records didn’t show any temperature anomalies. A call to the oil manufacturer found the oil used wouldn’t show signs of varnish until temperatures reached 160° to 170° F. The oil and/or excessive temperature didn’t seem to be the problem.

We did find that on occasion, the component filter was not changed when the visual dirt alarm was tripped. When they were finally changed, they would find the element had collapsed since the filter housing wasn’t equipped with a bypass check.

Pressures and flows all seemed to be reasonable and well below maximum limits for the piping and filter elements. Any idea what was causing the varnish? www.ifps.org | www.fluidpowerjournal.com

leave the shear-type directional valve in the blocked center position. He would do this to all six cylinders.

As the thick sheet of stainless would enter the rolls, they would be pinched or squeezed, causing the plates to straighten. If for some reason the plate would not submit to the squeeze, something had to give. The force pushing up on the rolls would reach 9,000 psi, and the cylinders would start to retract, allowing the warped plate to pass through.

The system worked well before the upgrade was installed.

The upgrade replaced the manual shear-type directional valves with solenoid-operated, three-position directional valves mounted on a manifold. The new directional valves were the sliding spool type with float centers. All of the old plumbing and hoses were replaced with new stainless tubing and hoses.

The installation really looked nice and professional.

(See attached circuit for a typical cylinder circuit.)

After the system was started and debugged, the workers ran a warped plate through the machine and found it would not straighten the plate. The plate would just pass under the cylinders, pushing them up and not causing any force to straighten the plates. They felt that surely it was just air in the cylinders and all they had to do was bleed off all the trapped air. However, bleeding the air did not help the problem.

During the troubleshooting process, they found all the PO check valves were leaking, so they ordered rebuild kits. After verifying the rebuilt checks would hold pressure, they re-installed the PO checks, bled all the air out, and still had the same problem of the cylinder backing off.

Any idea what the problem could be?

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

Solution:

During my inspection for the cause of varnish build-up, I looked for any of the normal reasons and found none. In fact, the oil temperatures were unusually low for systems like this. I was stumped and did not like the feeling.

I contacted a couple of people I felt were highly versed and experienced in fluid power and explained the problem. Greg George, IFPS Board member and senior hydraulic specialist for Walt Disney World felt the situation was due to an unusual problem of static electrical discharge in the filter elements. He forwarded information on a study conducted by Dr. Akira Sasaki.

Dr. Sasaki conducted studies on varnish problems with lubricating and hydraulic oil in gas turbine systems. He quoted, “The new and better synthetic and glass filter media has created unexpected side effects caused by the tighter filter pore sizes to remove fine sediment with high filter flux rates (flow rates per unit of area) to reduce capital costs.” The unexpected side effects were electrical spark discharges inside the filter element.

I was convinced the customer was experiencing this side effect in the glass media filters resulting in electrical spark discharges. This can cause local oil temperatures to exceed 1000°C. Elevated temperature IS the major cause of varnish.

The fix was to install longer filter bowls with longer filter elements to reduce the oil velocity going through them, thus reducing the potential for static electrical discharge.

Correction:

In the May/June 2010 issue, the equation printed in the solution to "Rod Gland Failure Problem on a Molding Press" is incorrect. It should be Minimum ratio needed = (max operating PSI allowed x cap area) / [rod end area (or annulus area) x maximum allowed PSI] - Load September/October 2010 | 19

Fluid Power Case Study:

By Bosch Rexroth Corporation

1

Intelligent

H y d r a u l ics

D

avis-Standard LLC builds equipment for the plastics industry and has a long history of producing quality machines for foam, flexible, and rigid sheet plastics extrusion. Their fully integrated extrusion solutions are at work in packaging, automotive, building trade, medical, and many other industries. Thanks to the combined efforts of Rexroth and its local distributor, Airline Hydraulics, Inc., the company can offer its customers a leap forward in precise gap control technology. Airline and Rexroth provided an alternative system solution to replace the existing hydraulic “hands-free” gap control system.

Hands-free gap control has substantial advantages over mechanical gap control found on traditional rollstack machines. In plastics production, a rollstack machine draws raw polymer material between heavy rollers, which cools the material and gives the plastic sheet its desired surface finish and thickness. Thicknesses range between 0.008 in. (0.2 mm) to over one inch (25 mm) depending on the application, which often includes pharmaceutical containers, consumer products packaging, arts and crafts products, film, and much more.

Producing plastics for these applications requires precise control of the distance between rollers to control thickness, which is exactly what the com20 | September/October 2010

Make Plastic Sheet Extrusion Faster, Simpler, and Safer –and Smarter pany wanted to provide: precise gap settings that can be changed in a matter of seconds.

Traditional gap setting and control methods are based on mechanical devices such as lever arms and pancake cylinders, which are nudged to the desired position according to the given product on the production line. Operators must also enter the nip area (where heavy nip rolls pull material out of the machine) and perform manual calibration using feeler gauges. Not only is this a potential safety hazard, but it can also be more difficult or time consuming to change gap or force requirements for different products. Once set, the gap can also be difficult to monitor using traditional feedback methods because machine frames can flex under heavy loads, causing slight discrepancies in positioning. In addition, the use of numerous mechanical components can cause maintenance and inventory issues.

To help customers become more flexible in their manufacturing, Davis-Standard addressed these

challenges on its XP Express™ roll stand system using Rexroth industrial hydraulics components to provide the intelligent control that allows customers hands-free flexibility for quick and smooth gap or force changes.

The key to the hands-free system is electronic control of the hydraulic cylinders that actuate the chill rollers, including digital position feedback to monitor cylinder positioning at any time. The chill rollers measure 36 inches in diameter by 80 inches wide, weigh about 5,000 pounds each, and can process more than 7,000 pounds of material per hour. Electrohydraulic components allow positioning to be maintained at specifications down to 0.0001 inch.

“The gap setting is the key to producing the finish customers want for their plastic products,” said Larry Mellow, project manager at Davis-Standard.

“We recognized that we could design a machine that would let electronic signals and transducers, not mechanical parts, control the gap settings and force. Now we have a way to adjust those settings almost instantly for more flexibility in product runs.”

Davis-Standard worked with Airline Hydraulics, who recommended the Rexroth intelligent system—specifically, four HACD digital controllers, each one commanding a CST4 hydraulic cylinder with a 3.25-inch bore and a stroke between 5 and 12 inches. There are two hydraulic cylinders per roller (one at each end) with each cylinder www.ifps.org | www.fluidpowerjournal.com

controlled independently. That allows the operator to change settings or “float” either end of the roll separately if necessary. The HACD controllers communicate digitally to a third-party PLC via DeviceNet or Profibus and receive signals from both digital SSi linear position feedback and analog pressure transducers. The digital position feedback enables one-micron resolution. The pressure transducers allow force to be limited if desired.

The force can be monitored and used for feedback for the overall process. The controllers also supply command signals to 4WRPEH servo solenoid proportional valves, which ensure smooth control of the up and down roll motion. The servo valves and pressure transducers come fully assembled on the hydraulic cylinders and require no assembly time. The hydraulic pressure in the system generally ranges between 2,000 and 2,500 psi but can go as high as 3,000 psi for larger sheet products.

Mechanical components in the form of linear guide rails were recommended for carrying the bearing blocks associated with the rollers. The rails are 35-mm to 45-mm wide and range in length from 396 mm to 575 mm. The linear motion components are an ideal choice for translating electronic precision into accurate mechanical motion.

The final element of the hands-free gap control system was a custom manifold containing the components needed for emergency retraction of the chill rolls if necessary.

In position control, which can be changed by the operator during the process, Mellow said the chill roll gap is keyed into the system along with the production recipe (including melt temperature, chill temperature, nip pressure, line speed, etc.). With linear transducers handling the position sensing, the roll gap is held constant. Gap changes can be made through the system while in operation, usually in seconds. If force control is chosen, hydraulic force expressed as nip roll pounds-per-linear inch is keyed in and force is maintained by the computer’s digital feedback system. Force changes, too, can be made “on the fly.”

Many products such as embossed plastic or those with a high-gloss finish run best by running a primary nip in position (gap) control mode with a secondary nip in force control mode. That allows the operator to use the chill roll “float” capability to impart a final polish to the sheet. When operating in either force or position modes, the alternate mode is displayed as a reference. All information is digitally stored and recorded.

The electrohydraulic system also makes it easy to set force limits for extra protection measures.

“Operators can input a lower force setting for the second chill roll, which they couldn’t do before,” Mellow explained. “If the nip detects a force change from foreign matter passing through, it can be set to open automatically. This helps reduce the risk of damage to the roll or plastic sheet.”

The companies also worked to solve the tricky problem of frame flexing. Recognizing that some flexing was inevitable if the machine was to have high-load capabilities, they changed the position feedback system so that key feedback components were not on the hydraulic cylinders. Instead, the feedback components are placed on the bear-

4

2

3

ing blocks at the end of the rolls, where a magnetic sensing system allows excellent position monitoring.

Changeovers for different production requirements can be made in seconds without shutting down an entire line. The HACD system reduces the need for operators to interpret feeler gauge readings and use trial-and-error methods to determine the right settings. That, in turn, minimizes wasted material caused by improper settings, or settings that become invalid due to flexing or vibration.

Once the recipe is keyed in, the intelligent hydraulics immediately begin controlling material output exactly as customers demand.

“The more changeovers a customer has, the greater the gain in productivity from using a handsfree system,” said Mellow. “It also maximizes operator safety, virtually eliminating the need to enter the nip area to make adjustments and changes.

This can help users to produce a wider variety of plastic products and increase return on investment even more.”

Figure Captions

Fig. 1: Using an electrohydraulic system, the XP Express offers hands-free gap control with substantial advantages over the mechanical gap control on traditional roll stack machines.

Fig. 2: With the HACD controller, gap changes for the rolls can be made through the system while the machine is in operation, usually in seconds.

Fig. 3: Servo valves and pressure transducers come fully assembled on the hydraulic cylinders and require no assembly time.

Fig. 4: Proportional valves ensure smooth control of the up and down roll motion.

For more information, visit www.boschrexroth-us.com.

Avert Fluid Leak Disasters!

Some industrial fluid systems operate under extremely high pressure. So leaks can not only lead to equipment breakdown and production delays, but serious personal injury as well. Fortunately, there’s the Spectroline® OPK-340 Leak Detection Kit. It’s the most effective, efficient and safest method for finding leaks in hydraulic, oil, water and water/glycol-based industrial systems. And best of all, it finds these leaks long before disaster strikes!

Kit includes: • OPTIMAX™ 3000 super-high intensity cordless, rechargeable blue light LED leak detection flashlight • 16 oz twin-neck bottle of patented OIL-GLO™ 44 concentrated fluorescent dye for synthetic and petroleum-based oils and hydraulic fluids • 16 oz twin-neck bottle of WD-802 concentrated fluorescent dye for water-based systems • 8 oz spray bottle of GLO-AWAY™ dye cleaner • Smart AC and DC chargers, fluorescenceenhancing glasses and a rugged carrying case.

To learn more, call 1-800-274-8888 or visit: www.spectroline.com

ISO 9001:2008 CERTIFIED COMPANY

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September/October 2010 | 21

FallLiterature

Review Special Advertising Section

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PNEUMATIC COMPONENTS AND SYSTEMS Air Logic Air Logic designs and manufactures a comprehensive line of pneumatic and vacuum control equipment. The control elements include both fluidic and moving diaphragm control components, each to be used for their own advantages.

The catalog includes: Modular Precision Regulators & Manifold Systems, Pressure and Vacuum Switches, Pneumatic Accessories, Miniature Quick Disconnects, Plastic Fittings, Assortment Kits, and Interface Devices.

Air Logic Tele: (800)558-5950 Fax: (262)639-5996 www.air-logic.com

No Challenge is too big or too difficult Allied Metrics Seals & Fasteners, Inc.

EXAPOR®MAX2 ARGO-Hytos, Inc.

Allied-Metrics specializes in Metric Seals and Fasteners for repair maintenance and manufacturing. We supply virtually all European, Japanese and U.S. Standard sizes for Hydraulic and Pneumatic Applications.

Allied-Metrics can fill practically any sealing requirement, any size, any material and any quantity from one piece on up.

The structure of the specially developed multi-layered filter material was designed for optimum performance, using glass and polyester fibers of different finenesses combined with an improved backing fabric (patent applied for) made of stainless steel and polyester. For the User, these improvements bring: • Longer service intervals • Higher operational reliability • Better oil cleanliness • Increased power density • Greater recognition value • Reduced operating and maintenance costs

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Innovation in filtration

The new generation of filter elements

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Benchmark Check Valves Attica Hydraulic Exchange Corp.

MAHLE Hydraulic Filters Behringer Corp.

Attica is proud to introduce the Benchmark line of hydraulic check valves. These In-Line, Right Angle, and Manifold mounted valves are direct operated and allow free flow of fluid in one direction only.

This is in line with Attica’s continued commitment to serve customers with high quality products from stock that provides the highest value available.

Since the early 1960s MAHLE has been active in the filtration of hydraulic fluids and lubricants.

The MAHLE Group’s superior technical expertise and excellent product quality have made the MAHLE Industrial Filter unit one of the world’s leading manufacturers of filter systems, equipment and accessories for fluid technology.

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Expanded Hydraulic Range CEJN Industrial Corporation

Hydraulics

High working pressure for a more versatile application range - With an approved working pressure up to 7250 PSI, in static applications, the products in the CEJN Hydraulic Range Catalog feature a higher working pressure than other products on the market. CEJN has widened its standard range of hydraulic quick connect products to include a full range of products for all types of hydraulic applications.

CEJN’s Hydraulic Range

Synonymous with quality, high performance and safety

CEJN Industrial Corporation (847) 263-7200 customer.service@cejnusa.com www.cejn.us

NEW Clippard Pneumatic Control Devices Catalog | Clippard Instrument Laboratory, Inc. Clippard, a manufacturer of the most complete line of miniature pneumatic products, offers a 356-page full product line catalog with technical information, product applications, and more. It includes features, specifications, photographs, and technical drawings for over 5,000 standard products. It's your complete source for miniature fluid power products. Request your free copy today!

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Clippard Instrument Laboratory, Inc. 7390 Colerain Avenue Cincinnati, OH 45239 877-245-6247 www.clippard.com/catalog-f

Free Fluid Power Motion Control Design Guide Delta Computer Systems, Inc. Delta Computer Systems’ newlyexpanded 64-page practical design guide covers 16 technical topics for fluid power system designers and engineers including tips on open and closed loop motion control, component selection of accumulators, valves, and cylinders, sensor resolution hints, and techniques for tuning and optimization.

For a free copy, visit www.deltamotion. com or call 360-254-8688.

Delta Computer Systems, Inc. 1818 SE 17th St. Battle Ground, WA 98604-8579 Phone: 360-254-8688 Fax: 360-254-5435 www.deltamotion.com Request more information at www.fluidpowerjournal.com

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September/October 2010 | 23

Request more information on web marketplace advertisers at www.fluidpowerjournal.com

Maximum Efficiency Hydraulic Fluid Evonik RohMax

PRODUCT LINE OVERVIEW CATALOG ExpresSeal

Designed to increase power, efficiency and performance, Maximum Efficiency Hydraulic Fluid (MEHF) will also help equipment builders, fleet managers and equipment operators save money while benefitting the global community. For more information or to calculate your own cost savings, visit www.mehf.com.

The fastest way to get the hydraulic and pneumatic seals you need.

Standard and custom machinable profiles from 1/2" to 21" O.D. including metric sizes, produced and shipped within days. Material available include Polyurethane, Nitrile (Buna-N), H-NBR, Viton®, EPDM, Silicone, Hytrel®, Teflon®, Filled Teflon®, Engineered Plastics, Carbon Steel and others.

Evonik RohMax USA, Inc. +1 888 876-4629 info@mehf.com

For more information, call 1-800-446-4773, visit www.expresseal.com or email: exinfo@expresseal.com

Profiles Update Materials:

Symmetrical ID / OD Seals

DS106

DK124

Rod / Shaft Seals

DS107

DS108

DS110/112

DS121

DS139

DK139

DS130

DS126/128

DS101

DS102

DS103

DS104

DS105

DS124

DS125

DS129

DS131

DS138

Rotary Rod / Shaft Seals

Piston / Bore Seals

Rod / Shaft Wipers

Wear Bands Back-Up Rings Bushings

Haskel’s new Pneumatic Driven Liquid Pump brochure, featuring high pressure pumps with output pressures to 100,000 psi (7000bar), contains updated technical and product information to guide users in preselecting the pump ideally suited for their application, including a new and comprehensive Performance and Specification Overview Chart with Pump Performance Data, and Guidelines for Continuous Duty and Applications for Maximizing Seal Life Performance.

The 2010 Seal Catalog contains over 400 pages of inch and metric seals in the most popular styles. The easy to use format quickly enables you to locate u-seals, piston seals, wipers, o-rings, piston rings, buffer rings and much more. Each listing includes seal material, temperature, pressure specifications and a cross-sectional drawing. A color index has been added with enlarged profiles for ease of identification. Most items listed are in-stock and ready for overnight delivery. Online ordering is now available at www.HerculesUS.com Hercules Sealing Products Phone: 888-617-6389 Fax: 800-759-6391 www.HerculesUS.com

DS238

DS116

DS117

DS119

DS141

DS142

DS216

DS120

DR102

DR103

DR104

DR105

DR106

DR107

DR108

DR110

DR111

DR112

DR117

DR201

DR202

DR203

DR2–4

DR205

DR206

DR207

EXR108

DK116

DK117

DK101

DK102

DK103

DK104

DK105

DK108

DK120

DK122

DK123

DK125

DK127

DK138

DK109

DK140

DK141

DK142

DK216

DA101

DA102

DA103

DA104PN

DA105PN

DA106PN

DA107

DA108

DA111

DA112

DA113

EXA113

DA114

DA115

DA116

DA211

DA212

DA213

DF106

DF107

DF108

DST113

DFL103

DFL104

DF101

DF102

DF103

DF104

DF105

DST108

DST109

DST110

DST111

DST112

Compressed Air Filtration La-Man Corporation

Lightweight high pressure bladder accumulators | Lightning Hybrids Inc.

Brochure offers a comprehensive overview of the company’s complete line of compressed air filtration products. Highlighted is the patented family of Extractor/Dryers. These two-stage, point of use filters remove contaminates to a 5-micron rating with flow ranges of 15 to 2,000 scfm.

Additional products available include the SuperStar Membrane Dryer, .01 Micron Filter, Refrigerated Extractor/ Dryer, and much more.

Lightning Hybrids Inc. (LHI) is dedicated to providing enhanced hydraulic system performance and efficiency without compromising safety and reliability. Our high pressure composite bladder accumulators for hydraulic and other energy storage applications are one-third the weight of standard steel accumulators and are safer, more efficient and priced comparable to steel accumulators.

For more information or to place an order contact:

DK119

DK222

Information Technology Solutions

BENEFITS Our high pressure composite bladder accumulators for hydraulic and other energy

Lightning Hybrids Inc. (LHI) is

storage applications are the same price and

dedicated to providing

one-third the weight of standard steel

enhanced hydraulic system

accumulators and have the following bene-

performance and efficiency

fits:

without compromising

Energy savings due to significant weight

safety and reliability.

reduction Our tanks are manufactured

Increased safety due to burst testing to

by Structural Composites

a safety factor greater than 3.4 times op-

Industries, a subsidiary of

erating pressure AND inherent leak-before

Worthington Cylinders, a

- burst fatigue failure mode

world-recognized leader in

Lighter accumulators are less expensive

high pressure tank manufac-

to ship and install since weight and

turer with an impeccable

mounting hardware is minimized

safety record.

Same price as similarly sized steel blad-

an impeccable

der accumulators

Lightning Hybrids accumulators are: Full peripheral impact and abuse testing including sidewall region Tested to over 500,000 cycles, currently testing Burst tested to a safety

Lightning Hybrids, Inc. 319 Cleveland Ave. • Loveland, CO 80537 1-800-223-0740 x104 www.LightningHybrids.com

1-800-446-4773

Lightweight High Pressure Bladder Accumulators

up to 3 million cycles

24 | September/October 2010

O RING

DS109

DR101

If you don’t see what you need, contact us for custom profiles.

2010 Seal Catalog Hercules Sealing Products

La-Man Corporation (800) 348-2463 www.laman.com

• Polyurethane • Nitrile (Buna-N) • H-NBR • Viton® • EPDM • Silicone • Hytrel® • Teflon® • Filled Teflon® • Engineered Plastics • Carbon Steel • Stainless Steel • Aluminum • Brass • Bronze

Gaskets

Pneumatic Driven Liquid Pump Brochure Haskel International

Haskel International, Inc. Ph 818 843 4000 www.haskel.com

The fastest way to get the seal you need.

Machinable Profiles 1/2” to 21” O.D.

factor greater than 3.4 times operating pressure Compliant with applicable standards of USDOT

OPERATION DESIGN

The bladder accumulator has a fluid section

LHI’s accumulators consist of a spun carbon

and a gas section, with the bladder acting as

fiber wrapped vessel with an aluminum lining,

a screen between the two. The fluid around

a nitrogen gas compression bladder and ports

the bladder is part of the hydraulic circuit, as

for fluid flow. The gas and fluid sides are sepa-

the accumulator draws in fluid, the pressure

rated by a bladder. LHI’s carbon fiber pressure

increases in the bladder by compressing the

shell is considerably lighter than a steel shell.

gas. When the pressure drops, the com-

For example, our 15 gallon accumulator weighs

pressed gas expands and forces the stored

115 pounds/55 kilos compared to 465

fluid into the circuit.

pounds/210 kilos for a steel accumulator.

CPPC (gas transport and fuel tank) and ANSI/CSA NGV2

Lightning Hybrids accumulators are made and assembled in the USA.

For more information or to place an order contact Bonnie Trowbridge: 1-800-223-0740 x 102 bonnie@lightninghybrids.com 319 Cleveland Ave. Loveland, CO 80537

www.ifps.org | www.fluidpowerjournal.com

Hydraulic Flanges and Components Main Manufacturing Products Catalog includes the popular styles of MAIN Manufacturing’s extensive offering of Hydraulic Flanges and Components –ready for immediate shipment.

Dimensional drawings, part numbers, metric and weld specifications included.

The “Quick Reference Guide” helps specify less popular items often stocked or quickly manufactured at our US plant.





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MAIN Manufacturing Products, Inc. Grand Blanc, MI (800) 521-7918; FAX: (810) 953-1385 E-mail: info@mainmfg.com Web: www. mainmfg.com/fpj

Multiple Modular Pumps Marzocchi Pumps USA Corp.

A complete range of ALP and GHP modular elements. Displacement from 0.19 to 200 cc/rev, group 0.25, 0.5, 1, 2, 3, 4. Offering total connectivity for limitless possibilities. Marzocchi Pumps USA Corp carries a full line of gear pumps and motors. For additional product literature, please contact us at (800) 924-5404 or visit our website www.marzocchipumpsusa.com.

For more information, call us at 800-924-5404 or visit www.marzocchipumpsusa.com

     

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© 2010 Inserta Products, Inc.

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Allied metrics

seals & Fasteners, inc.

Your One Stop Source for Sealing Solutions Complete Line of Equipment Oil-Rite Corporation A NEW full color 104 page catalog is available on Oil-Rite’s Lubrication Equipment featuring PurgeX® Centralized Lubrication Systems. Complete “turn key” systems are available for immediate delivery. Liquid or Grease delivery. Air or Electric Motor Operated. The catalog also features an entire line of level gauges, lubricators, valves, vent plugs and filters.

Oil-Rite Corporation PO Box 1207 Manitowoc, WI 54221-1207 Telephone: (920) 682-6173 Fax: (920) 682-7699 E-mail: sales@oilrite.com www.oilrite.com www.ifps.org | www.fluidpowerjournal.com

Manufacturer and distributor of hydraulic seals, pneumatic seals, o-rings, oil seals & gaskets for all industries world wide

O-Rings

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September/October 2010 | 25

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Western Fluidyne – A10V Piston Pumps Western Fluidyne

YOUR CYLINDER SOURCE Yates Industries, Inc.

Western Fluidyne provides replacement A10V Piston pumps to distributors and OEMs all around the world. These high quality pumps come with a full range of options including seals, mountings, shafts, compensators, thru-drives, etc. Our customer service team provides what you want, when you need it. Most pumps ship same day or next. Give our Customer Service Team a call to assist you with your hydraulic needs!

All Designs, All Sizes, One Result.

Yates Cylinders – an ISO-9001:2008 company with facilities in Michigan and Alabama – is your top-quality supplier for all cylinder applications. Hydraulic, pneumatic, NFPA, millgrade, or custom engineering – you name it, Yates can handle it. Complete catalog available.

We also maintain an unmatched repair program used by the biggest names in the American Industry.

Western FluiDyne 31915 Groesbeck Hwy Fraser, MI 48026 800.842.5377

12/3/2008 11:06:48 AM

Yates Industries, Inc. www.yatesind.com Yates Industries South, LLC. 3401-J Highway 20 Decatur, AL 35601 ph 256.351.8081 fax 256.351.8571

Yates Industries, Inc. 23050 Industrial Dr. E. St. Clair Shores, MI 48080 ph 586.778.7680 fax 586.778.6565

Radial Piston Motors Young Powertech Inc.

Filtration, Manifolds, Valves, & Accessories Zinga Industries Inc.

Replacement for Staffa/Kawasaki, KYB, and Intermot Displacements from 100cc - 7000cc. Pressures to 4350 psi, Single and 2 speed, Tapered and straight keyed, internal and external splined Shafts, metric and SAE porting. Call or email for pricing and delivery.

Zinga Industries is a leading manufacturer of mobile hydraulic oil filters, tank accessories, and manifolds. From 5 PSI to 6000 PSI, tank top or spin-on, we have a filtration product to meet your needs. Hydraulic manifolds are custom designed for your specific application. Tank accessories are the best available, and standard equipment with major OEM’s. We are an ISO registered company, celebrating 30 years in the hydraulic filtration Industry (1976-2006).

Young Powertech Inc. Garnet Valley PA Email: info@yptius.com www.yptius.com Phone: 610-558-0760

®

Zinga Industries, Inc. • 2400 Zinga Drive • Reedsburg, WI 53959 • U.S.A.

www.zinga.com

26 | September/October 2010

(608) 524-4200 www.zinga.com

www.ifps.org | www.fluidpowerjournal.com

ProductReview

Continued from page 7

Liquid, Gas, and Foam Sensors

Fluid Components International The OEM level sensors and switches have thermal dispersion technology with solid-state or relay contact outputs in a wide range of materials independent of conductivity or dielectric constant and can resist a high degree of coating. Typical applications include point detection in liquid/gas, liquid/liquid, liquid/foam, and foam/gas interface applications. Standard designs include twowire loop powered, insertion type with pigtail, level and temperature, mass level with two-wire loop powered, integral type, high temperature, and wet/dry. www.fluidcomponents.com

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Hydraulic Filter Elements

Zinga Industries Inc. A product option is now available for the company's line of AE and ZAE spin on hydraulic filter elements. The patent-pending element shroud replaces the existing element gasket and provides additional environmental protection to the exposed portion of the element top. Designed to enhance the appearance of new machinery, the shroud addresses the issues of rust and dirt buildup on machines exposed to the environment. www.zinga.com

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Abrasion-Resistant Hose Cover

PIRTEK The PIRTEKTOR abrasion-resistant cover for hydraulic hoses was tested to ISO6945, which is the international standard that specifies the method for determining the abrasion resistance of the outer cover of rubber hoses. Under test conditions, the cover showed a much higher level of abrasion resistance when compared against hoses made with both standard and specialized rubber coverings.

In some very aggressive applications when equipment is working in demolition, excavating, landfill sites, and metal recycling facilities, another benefit is the addition of an external sleeve or a protective wire to the hose assembly. www.pirtekusa.com.

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September/October 2010 | 27

Press Loading with Vacuum

By Daniel Pascoe, General Manager, Vacuforce, Inc.

Fig. 1

Fig. 2

28 | September/October 2010

Steel stamping, as it is commonly referred to, is the process of taking a flat piece of steel through a variety of inline presses to eventually form a finished part such as an automotive body panel or other pressed metal part. The method of transfer employed in taking the panels from one press to the other is normally done with vacuum. The typical end of arm tool used is similar to the type shown in the image above, which consists of an extruded aluminum frame with various brackets holding vacuum cups, each connected to an individual vacuum venturi (compressed air powered). If the panel being handled is always the same shape and form, then this method of vacuum tool is adequate in being able to consistently pick and place the part accurately. However, if the part being handled changes shape and size frequently, then a more universal approach is required.

Fig. 1 shows a CAD drawing with an arrangement of different aluminum plates that have to be handled by a single vacuum tool. The biggest problem is the infinite arrangement of through holes, which change in both size and position depending on the part. To use a typical vacuum cup tool as shown above, would require continuous operator adjustment which, depending on the size of batch run, could be extremely time consuming. Therefore, Vacuforce was called upon to develop a solution for this application to offer maximum productivity with one single vacuum tool.

The Squid system (Fig. 2) was built and employed in this particular application. This particular Squid tool consists of 25 Ø40mm vacuum cups that are all connected to the same vacuum source.

However, the vacuum cup layout as shown in the CAD drawing in Fig. 3 are not all covered by the product. Therefore, in a traditional vacuum cup tool, these cups would “leak” and the remaining cups would not be able to achieve vacuum (unless the vacuum pump was enormous) and be able to compensate for the leak. However, The Squid employs a self-closing valve (Fig. 4), which in fluid power minds is a velocity fuse. If the valve experiences a vacuum flow because a cup was leaking or even damaged, the valve closes, isolating that particular cup from The Squid system, enabling full vacuum force on the remaining cups.

This method of cup isolation enables the integrator/user to be unconcerned as to what cups are covered and what cups are not by the product being handled. It also enables the vacuum source to be smaller than if the system had to compensate for vacuum leaks. The self-closing valve (SCV) requires as little as 0.5 cfm to close and as it is adjustable, it can be used on porous surfaces or very large diameter cups that have a larger internal volume.

This application requires very little other hardware. A manual application instead of the usual robotic installation employed an H frame pneumatic lifter and an external compressed air powered venturi for providing vacuum to two Squid systems in this tandem operation. The operator placed The Squid on the plates, turned on the vacuum venturi and lifted the parts into the press and then repeated the operation in reverse by picking up the pieces after the press operation without any concern as to the shape of the part or the number or position of the through holes.

Fig. 3 Redundant Vacuum Cups Placed Over Punched Holes

Fig. 4 The testing of this application can be viewed at http://www. youtube.com/ user/Vacuforce.

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

Vacuforce Inc. specializes in the application of vacuum systems and components for industry in North America. Daniel can be reached via the company’s Web site at www.vacuforce.com or directly at dpascoe@vacuforce.com.

www.ifps.org | www.fluidpowerjournal.com

Diagnosing and Correcting

Dieseling

Seal Failure

By Hercules Sealing Products

Those who do low-pressure repairs see many different types of seal failures, and many of the failures are easily diagnosed and corrected. For example, extrusion on the ID of a rod seal generally indicates excessive clearance between the rod and the throat of the gland. However, there are some types of seal failures that may be rarely seen and when encountered may not be understood.

An example of a failure model is Dieseling, which is the diesel effect in a hydraulic cylinder—the same as what happens in a diesel engine. A flammable liquid is vaporized in the presence of extreme heat and an “explosion” occurs.

All mineral oil contains molecularly dissolved air. At atmospheric pressure, approximately 9% of the volume of hydraulic oil is comprised of dissolved air. In a “saturated” condition, air molecules are mixed or attached to the oil molecules.

In this situation, the dissolved air has no effect on the performance of the hydraulic oil, not even on the compression modules.

However, the volume of saturated air rises directly in proportion to the pressure acting on the oil. This means that at high pressure, large quantities of air will be dissolved in the oil. The percent of molecularly dissolved air increases in direct proportion to the increase in pressure.

If the pressure on the oil falls, the high volume of air molecules can no longer remain in solution, and the air will separate and form bubbles. The presence of air bubbles in the hydraulic oil may now be evidenced by “spongy” operation of the system.

When this drop in pressure occurs very rapidly (i.e. high-pressure oil bypasses across a seal surface from extremely high pressure to the low pressure side of the seal), the change in energy will take the form of heat and in extreme conditions may actually cause an ignition of the vapors of the oil present in the air bubbles that will burn the seal. There are studies that have shown temperatures of 1000°C being reached in the most extreme conditions.

Generally this condition may be exhibited more frequently in cylinders, which are cycled very rapidly, but it is not exclusive to this type of operation.

Request more information at www.fluidpowerjournal.com

Top Left: Melted/burned seal material under expander Top Right: Two piston u-seals exhibiting evidence of pressure trap, air entrapment in seal material, and dieseling (Note the burned seal area on the lighter of the two u-seals.)

Left: Close up of one of the u-seals showing melted portion of urethane and “craters” caused by the air rapidly escaping from the seal material

For more information, visit www.herculesus.com.

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September/October 2010 | 29

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

Something is

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here is something missing in my repertoire of fluid power components. Can you help me?

A couple of months ago, in the Off-Highway edition of the Fluid Power Journal, Brian Hageman had an article on a new hydraulic pump. How many of you read it? Keep your hands up. Oh, you intended to read it but never got around to it. I see. Ok, you can put your hands down now. We are going to discuss some of the implications of what was presented in the article, so those of you who read it can stay with me. The rest of you need to go back and read the article. When you have finished, you can come back here and catch up.

Brian opens the door to the discussion of using fluid power as an efficient and environmentally friendly way to capture and transfer energy. Now, in his article, he is promoting a device where heat energy derived from waste, solar, geothermal, and even internal combustion is converted directly into hydraulic energy, but the fact is that alternative energy from heat, wind, or ocean waves would be more efficiently captured if the energy was converted directly and used as fluid power. The problem as I see it is two-fold: there is the assumption that alternative energy needs to be converted to electricity in order to be used, and we do not promote an economical way of directly using stored energy.

I am not saying that all electrical systems could be replaced with fluid power.

We would be hard pressed to provide lighting, toasters, computers, and microwave ovens driven by fluid power, but for many industries, the major energy requirements are for rotary and linear motion. This is where we should really shine. The fact is that we could replace almost every electric motor in a facility with a hydraulic motor and operate more efficiently. If the hydraulic energy was produced by an alternative energy device, then this is doubly true.

How many of you believe that? No, really… give me a show of hands. How many of you actually believe that? I see some enthusiastic hand waving, some tentative half-mast waves, a bunch of blank stares, and a group of petulant grumps who are thinking, “That will never happen.” This is important. If we are not convinced, we will never be able to encourage others to move outside their comfort zones and try something new. But being convinced is not enough. We have to be right, and we have to have the knowledge and the components to follow through.

There is no question that we have the ability to capture and store energy using fluid power. Where we are weak is in the area of using the energy efficiently. Pneumatic folks have an advantage here because they are used to storing energy at a higher than required pressure and then using a regulator for a controlled release. But hydraulic aficionados typically store the energy at high pressure and then use flow controls or pressure-reducing valves for the controlled release. This can be a huge waste of energy that is directly proportional 30 | September/October 2010

to the ratio of the pressure stored and the pressure required where the work is being done. (See the article on "Reducing Pressure: A Way to Save or Waste Energy," Jan/Feb 2010 issue).

If we are to successfully replace electric motors with hydraulic motors, we need to understand how an electric motor uses energy and then mirror that process and even improve on it. Let’s take a look at a typical AC motor application with a varying load and, without getting too technical, talk about what goes on electrically.

The speed of the electric motor is established by the windings and the frequency. The torque available is a factor of the voltage and the current through the motor. It is important to remember that there is never a time when there is no load on a rotating motor. Energy is required for the developing and collapsing magnetic fields as well as for overcoming the resistance to motion from the rotating components. You may have heard the expression “no load amps,” which is a bit of an oxymoron. It describes the power consumption of an electric motor when there is no external resistance on the shaft. The “no load” power consumption is typically one third of the fully loaded condition.

On start up, there is a large inrush of current as the windings develop the magnetic fields and the motor mass accelerates to its rated speed. A few milliseconds later, when the motor is at rated speed, the current settles down to what is needed to maintain that speed against the resistive load. As the load varies, the voltage is constant and the speed stays the same. It is the current that changes to match the load. There is no metering for a standard electric motor. The speed and voltage are continuous. Only the current changes to match the load.

So the question is, how can we mirror that process and do it even better?

We will begin by using a variable displacement hydraulic motor. For the sake of the illustration, let’s assume a power source that will be capable of sufficient flow and with a fixed pressure that will provide enough torque to meet the speed and load requirements with the motor at maximum displacement. To control the displacement of the motor, we will provide a tachometer that senses the rpm of www.ifps.org | www.fluidpowerjournal.com

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the motor shaft. The displacement is spring biased to maximum. We now have a system that can mirror the characteristics of a standard electric motor.

As in the electric motor, there is never an actual “no load” condition. Pressure and flow are always required to rotate the motor. With a variable displacement motor, the minimum displacement can be near zero and so the available torque would also be near zero no matter what the available pressure may be. (Torque = pressure x displacement / 2π.) For any given motor speed, available pressure, and external resistive load, there will be a discreet displacement to match that speed.

On start up, there is an inrush of flow (current) at a fixed pressure (voltage) as the motor mass at full displacement accelerates to its rated speed. A few milliseconds later, the tachometer commands the displacement to diminish until it reaches the discreet location for the speed and resistive load. As the load varies, the displacement and flow (current) will change to match the new requirement but all the while remaining at the same speed. All this is without the accompanying pressure drop across a flow control or pressurereducing valve.

So, we can match the functionality of the electric motor, but can we do better? Absolutely!

This is what we can do: We can provide a soft start with no additional controls. We can provide variable speed without having to add an expensive variable frequency drive. We can provide rapid reversing. We can do many starts and stops per hour without special equipment. We can provide high speed/low torque or low speed/high torque without the expense of gear boxes. We can fit our motors into more compact spaces because of a higher power density. We can place our motors under water and/or in locations where there would be the danger of explosion if there were a spark.

In our illustration, we used a fixed pressure, but in reality we could use a variable pressure and achieve the same results. This throws open the door to efficiently using accumulators to store alternative energy converted to fluid power.

So, what’s missing? Controlling displacement is relatively easy using electronics, but I think if we are going to be successful in replacing electric motors, we will need to have a simpler and less expensive way of doing it. I am not aware of any hydraulic motors in production where there is a non-electronic sensor to control displacement based on rpm. If you know of such a device, please contact me and let me know.

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September/October 2010 | 31

The

Pressure-Flow conundrum

In

most hydraulic (fluid power) applications, there are essentially two ways to get the required power output: high flow at (relatively) low pressure and low flow at high pressure. This is, of course, because power is a product of flow and pressure; increase pressure and you can reduce flow proportionately but still get the same power output. For example, 100 liters/minute at 200 bar equates to the same power output as 50 liters/minute at 400 bar.

Higher pressures mean higher force and torque is available from smaller components. And because these components are smaller in displacement, higher speeds are possible from smaller flows. Smaller flows mean pipe work, valving, and even the tank can be made smaller – remember, the old rule of thumb for tank size (largely ignored these days) is three to five times pump flow per minute.

So the power density of individual components and the system as a whole increases with pressure. But there are a number of disadvantages with higher operating pressures: • The inherent heat dissipation of the system is lower due to the reduced surface area of the tank (it’s smaller in volume), pipe work, and components. In other words, a bigger heat exchanger is required for a high-pressure system of the same power and efficiency.

• Greater variation in fluid volume (compression) at higher pressures means reduced stiffness of the system and less favorable dynamic response.

• Higher noise levels as a result of higher peak pressures.

• The potential for greater friction and wear, resulting from heavier loads on bearings and sliding surfaces, and more severe damage resulting from aeration, cavitation, and micro-dieseling due to higher compression ratios.

• Increased potential safety hazard from components and conductors containing fluids at higher pressures.

In the majority of applications, though, the advantages presented by higher operating pressures outweigh the disadvantages. Which is why for several decades now, we’ve seen the average operating pressures of hydraulic equipment – particularly mobile hydraulic equipment – increase (Fig. 1).

And this is a trend that is expected to continue. But clearly it comes with some design problems. Here are a few that come to mind: • Heavier hose construction, i.e., less flexible lines, longer bend radii, and possibly, special fittings and assembly methods.

• Heavier valve bodies, actuators, pumps, pipes - or the use of more exotic and expensive materials in their construction.

• More advanced seal materials, new groove designs, and closer tolerances - to ensure sealing integrity doesn’t suffer.

32 | September/October 2010

About the Author Brendan Casey has more than 20 years experience in the maintenance, repair and overhaul of mobile and industrial hydraulic equipment. For more information on reducing the operating cost and increasing the uptime of your hydraulic equipment, visit his Web site: www.HydraulicSupermarket.com * Source Ohkawa, S., Konishi, A., Hatano, H., and Voss, D., “Piston Pump Failures In Various Type Hydraulic Fluids,” Hydraulic Failure Analysis: Fluids, Components, and System Effects ASTM STP 1339, G. E. Totten, D. K. Wills and D. Feldmann, Eds., American Society for Testing and Materials, West Conshohocken, PA, 2001.

These issues help explain why, although the average operating pressure of hydraulic excavators has been on the increase for over 30 years, they haven’t changed much since the current average operating pressure of 350 bar was reached in the early 1990’s (Fig. 1).

But beyond these design and material-strength issues, also consider for a moment how higher operating pressures impact machine reliability.

We know that force in a hydraulic system is a product of pressure and area. So when operating pressure increases, so do loads on lubricated surfaces.

Oil viscosity and film strength are vital to maintain fullfilm lubrication between heavily loaded contacts. I already consider the oil to be THE most important component of any hydraulic system. But this will definitely be the case for machines operating at increased pressures. Oil selection AND maintenance will be critical for optimum reliability.

Similarly, contamination control will be more important than ever. Because the more heavily loaded the lubricated contacts, the more susceptible they are to wear and damage from water and particle contamination.

For machine designers, issues such as tank size, installed cooling capacity, filtration, contamination control, and oil recommendations will be even more important than they are now because the impact of mistakes or omissions in these areas at the design stage will have an even greater impact on machine reliability.

For hydraulic equipment users whose maintenance practices are unsophisticated or non-existent, their hydraulic equipment operating costs can only go up due to a likely higher incidence of premature failures resulting from temperature, lubrication, oil degradation, and contamination issues.

Figure 1

Fig. 1: Operating Pressure Trend of Hydraulic Excavators*

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NFPA | National Fluid Power Association

National Fluid Power Association Announces 2010-11 Board of Directors

T

he National Fluid Power Association (NFPA) has installed its 2010-11 Board of Directors. Gregory Willard, president & CEO of Quality Control Corporation, became NFPA’s 58th Chairman of the Board. During a recent ceremony, Allen Carlson, president of Sun Hydraulics Corporation and NFPA's immediate past chairman, and the other 2009-10 board members were commended for their leadership during the economic challenges that had presented themselves over the past fiscal year. According to Mr. Willard, “NFPA continues to be a strong, robust organization. We are dedicated to strengthening the position of the association and its members while advancing fluid power technology into the global marketplace.”

The NFPA’s 2010-11 Board of Directors Officers Chairman - Gregory Willard, President & CEO, Quality Control Corporation

Directors Immediate Past Chairman • Allen Carlson, President & CEO, Sun Hydraulics Corporation • Jeff Blackman, VP Automation Sales, Bosch Rexroth Corporation • William Gorski, President, Mead Fluid Dynamics • Scott Krueger, VP/Manufacturing Operations, Eaton Corporation—Hydraulics Group • Pat Lee, President, Fluid Power North America, Gates Corporation • Robert Mortensen, Executive VP & General Manager, HUSCO International, Inc. • Roger Sherrard, VP & President Automation Group, Parker Hannifin Corporation • Michael Scotese, General Manager, Poclain Hydraulics, Inc. • John Smith, President/CEO, ROSS Controls Council Liaisons • Jon Goreham, Regional Vice President, Alro Steel Corporation • Judy Wojanis, President, Wojanis Supply Co., Inc.

First Vice Chairman - William Parks, President, Deltrol Fluid Products Second Vice Chairman - James Western, President, Pall Aeropower Corporation Treasurer - R. Edwin Howe, President & CEO, Enfield Technologies Executive Director - Eric Lanke, NFPA Secretary - Sue Chase, NFPA

NFPA is Hosting Pavilion in the MDAMotion, Drive & Automation Sector at Hannover Fair NFPA is pleased to announce that it will host another pavilion in the MDA – Motion, Drive & Automation sector at Hannover Fair in spring 2011. The exhibition is scheduled for April 4-8, 2011 at Hannover Messe, Hannover, Germany.

NFPA’s group exhibit will once again offer participants a standard turnkey exhibit space including a fully furnished booth with full access to pavilion services and support. Organized by Hannover Fairs USA and Deutche Messe AG, the NFPA Pavilion assists exhibitors by reducing administrative and logistical concerns. Exhibitor information can be found at www.nfpa.com/ events/hannover.asp.

Staff from both NFPA and Hannover Fairs USA will be available to help exhibitors before and during the show. For more information, contact Sue Chase at 414-778-3376 or schase@nfpa.com. www.ifps.org | www.fluidpowerjournal.com

For more information about NFPA, please go to www.nfpa.com.

Calendar of Events PTC Asia 2010 October 25-28, 2010 • Shanghai, China NFPA’s Economic Update Webcast October 28, 2010 • 1:00 pm Central By: Alan Beaulieu, Institute for Trend Research AG CONNECT 2011 Expo January 8 - 10, 2011 Georgia World Congress Center, Atlanta, GA 2011 NFPA Annual Conference February 16 – 19, 2011 Hyatt Regency Coconut Point, Bonita Springs, FL IFPE 2011 March 22 – 26, 2011 Las Vegas Convention Center, Las Vegas, NV co-located with CONEXPO-Con/AGG. Visit www.ifpe.com for more details.

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

Request more information at www.fluidpowerjournal.com

September/October 2010 | 33

ESA | Equipment Service Association

2010 ESA Fall Tech Conference October 10-12, 2010 Embassy Suites Bloomington Minneapolis, MN www.2esa.org

FPDA | Motion & Control Network

Registration Open For FPDA/ISD Industry Summit October 5-8, 2010 • PGA National Resort & Spa, Palm Beach Gardens, Florida

Developed for fluid power, motion control, automation, and sealing professionals, attendees will discover the keys to success at the FPDA/ISD Joint Industry Summit, October 5-8, 2010 at the PGA National Resort in Palm Beach Gardens, Fla.

In addition to a program packed with take-home value, the PGA Resort is offering a competitive rate of $140 a night for accommodations.

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

Features include • Content-rich education sessions will discuss the latest in sales, marketing, and pricing strategies.

• A leading economist will provide up-to-date research framed to help support your future business decisions.

• A morning devoted to energy savings and sustainability efforts in the industry will feature a leading panel of industry experts, plus breakouts on regulatory issues, selling “green,” and energysaving applications and solutions.

• Participants will explore new products, solutions, and services during the new Supplier Showcase.

Combine these features with expanded networking opportunities, and you have a winning formula.

Those interested in registering for this event should visit www.fpda.org or call 410-940-6347 for details.

N DI No

lt Bo & D rs e ge to luD ar eC NC Ch NN s I tra Co KIt ex

Directional control SolenoiD ValVeS

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4040 Norex Drive, Chaska, MN 55318 • (952) 466-6220 Fax (952) 466-6219 • Toll Free: 1-800-222-1169 E-mail: mail@safewayhyd.com • www.safewayhyd.com All of our products are designed, manufactured and assembled in the USA. Request more information at www.fluidpowerjournal.com

34 | September/October 2010

• QualitY • Price • noW! Power Valve U.S.A. Houston, Texas www.powervalveusa.com service@powervalveusa.com 888-862-1064 Tai Huei Hydraulic Co., Ltd. ...machine tool quality from Taiwan Request more information at www.fluidpowerjournal.com

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IFPS | International Fluid Power Society

Last Call! Help Us Celebrate Our 50th Anniversary September 15-18, 2010 • Sheraton Society Hill • Philadelphia, PA Please join us September 15 - 18, 2010 as we hold the IFPS 2010 Annual Meeting and 50th Anniversary Celebration at the Sheraton Society Hill, Philadelphia, Pa. This is a great way to network with professionals in the fluid power and motion control industry.

An anniversary dinner will be held on Friday, September 17, 2010, where many Society friends and past presidents will help the IFPS celebrate its 50 years. Two optional tours of Philadelphia are also available.

In addition to committee and board meetings, a technical workshop, “Watts It All About? The Use & Misuse of Energy in Fluid Power Systems,” will be held on Saturday, September 18, 2010. Participation in this workshop contributes towards reaccreditation requirements.

Register by visiting www.ifps.org or by calling 800-308-6005.

Technical Workshop: “Watts It All About?”

The Use & Misuse of Energy in Fluid Power Systems Saturday, September 18, 2010 • 8:00 am – 4:00 pm (lunch included) IFPS Members: $125.00 / Non Members: $150.00 Join Dan Helgerson, CFPAI, and Jon Jensen, CFPAI, for a look at methods and measures to be taken in realizing energy savings in fluid power systems.

Dan will address the savings to be found in hydraulic systems including topics on • Flow Control • Right Sizing Prime Movers • Pressure Reducing Valves • Accumulators • Pressure Compensated Pumps • Load Sensing

Jon will lead the class in a look at common issues found in pneumatic systems, including examples and solutions for the top target areas of energy savings in pneumatic systems: • Leaks • Air Blow • Excessive Pressure • Intermittent Demand • Inappropriate Usage of Compressed Air Additional information and registration can be found by visiting www.ifps.org.

Hydraulic Specialist and Pneumatic Specialist Review Training Sessions Coming to St. Louis, Missouri Make plans now to attend the Hydraulic Specialist and Pneumatic Specialist review training sessions in St. Louis, Mo., the week of October 25, 2010. These review sessions are taught by an IFPS Accredited Instructor, and each session is a two-and-one-half (2-1/2) day program. The written certification test will be held in conjunction with each review session; additional test fees apply.

What’s Covered: Review training - Hydraulic Specialist (HS) and Pneumatic Specialist (PS) review sessions encompassing 20 hours of review training. You’ll learn how to • Use the math required for testing • Analyze and design systems • Select components • Prepare and properly take certification test Learn more about these and other training opportunities by visiting www.ifps.org and clicking on “Education & Training.”

Updated IFPS Study Manuals In a continuing effort to keep IFPS certification offerings on the cutting edge with changing fluid power and motion control technologies, panels of certified Subject Matter Experts have been hard at work updating many of our IFPS certification manuals.

The Pneumatic Technician, Industrial Hydraulic Technician, and Industrial Hydraulic Mechanic study manual updates are complete and are available for download by visiting www.ifps.org.

IFPS members can download all study manuals free of charge; non-members may purchase.

www.ifps.org | www.fluidpowerjournal.com

IFPS Calendar visit www.ifps.org Industrial Hydraulic Mechanic Review October 9, 2010, 8:00 a.m. – 4:00 p.m.

Bloomington, MN Industrial Hydraulic Written and Job Performance Test October 10, 2010 - Bloomington, MN Pneumatic Specialist and/or Hydraulic Specialist Review Training Week of October 25, 2010, St. Louis, MO Job Performance Test Technicians and Mechanics 10/29/10 - Altec Industries - Forest Park, GA

AssociationNews Certification Levels Available: CFPAI Certified Fluid Power Accredited Instructor CFPAJPP Certified Fluid Power Authorized Job Performance Proctor CFPAJPPCC Certified Fluid Power Authorized Job Performance Proctor Connector & Conductor CFPMM Certified Fluid Power Master Mechanic CFPIHM Certified Fluid Power Industrial Hydraulic Mechanic CFPMHM Certified Fluid Power Mobile Hydraulic Mechanic CFPPM Certified Fluid Power Pneumatic Mechanic CFPMT Certifed Fluid Power Master Technician CFPIHT Certified Fluid Power Industrial Hydraulic Technician CFPMHT Certified Fluid Power Mobile Hydraulic Technician CFPPT Certified Fluid Power Pneumatic Technician CFPS Certified Fluid Power Specialist (Must Obtain CFPHS, CFPPS) CFPHS Certified Fluid Power Hydraulic Specialist CFPPS Certified Fluid Power Pneumatic Specialist CFPE Certified Fluid Power Engineer CFPCC Certified Fluid Power Connector & Conductor CFPMIH Certified Fluid Power Master of Industrial Hydraulics CFPMMH Certified Fluid Power Master of Mobile Hydraulics CFPMIP Certified Fluid Power Master of Industrial Pneumatics

September/October 2010 | 35

AssociationNews Fluid Power/Pneumatics FIRST Scholarships Awarded Through its work in education and training, the IFPS and FPEF grow and advance the fluid power workforce. Both organizations are strong supporters of the FIRST Robotics Competition, which encourages high school students to participate in a mammoth robotics competition through FIRST (For Inspiration and Recognition of Science and Technology).

IFPS has awarded two $2,500 scholarships to high school seniors attending ABET-accredited colleges/universities that met certain criteria and used pneumatics in the design of their 2010 FIRST robots.

FPEF has awarded two $500 scholarships to high school seniors attending one of FPEF’s key schools that met certain criteria and used pneumatics in the design of their 2010 FIRST robots.

Key Schools consist of high schools, colleges, and universities that have formal fluid power programs.

A panel of five industry representatives from The Fluid Power Educational Foundation (FPEF) Board of Trustees reviewed all applications. After careful analysis, the FPEF Board has announced the winners: IFPS Scholarship Winners: Kyle Gagnon, attending University of New Hampshire and Anjian Wu, attending California Institute of Technology FPEF Scholarship Winners: Alan Rehfeldt, attending Milwaukee School of Engineering and Michael Sarzynski, attending Purdue University

IFPS | International Fluid Power Society

IFPS Newly Certified Robbie Allen, MHM Georgia Power Company

Dennis Garrett, S, HS The Boeing Company

Walter Barrett, PS

Isaiah Gault, MHM William Malcolm, V, MHT, Southern California Edison Hydraulic Supply & Service Co. John Granus, MM, IHM Western Hydrostatics, Inc. Billy McKissick, MHM Georgia Power Company Jeffrey Greene, MHT Georgia Power Company Chris Mussetter, IHM Kellogg Chad Hamilton, IHM Kellogg Jeff Phelps, MHM Ameren Corporation Richard Harris, CC The Boeing Company Arthur Ramsey, Jr., MHM

Daron Bircher, MHM Ameren Corporation Christopher Brunner, IHT, Spevco, Inc. Joe Chapman, PM, IHM, Kellogg Herminio Dias, MHM Georgia Power Company John Dudley, PM, IHM Kellogg

George Heid, IHM Controlled Fluids, Inc.

Jerry Fie, MHM Keith Householder, PM, Southern California Edison IHM, Kellogg Dustin Fletcher, MHM Ameren Corporation

Thomas Johnson, PM, IHM, Kellogg

Ryan Francisco, HS Western Hydrostatics, Inc.

Robert June, PM Western Hydrostatics, Inc.

Aaron Fruhling, MHM Ameren Corporation

Matthew Kessler, MHM Ameren Corporation

Luis Larin, PT Western Hydrostatics, Inc.

David Smith, MHM Georgia Power Company Gavin Smith, CC The Boeing Company Joshua Soper, HS General Dynamics Wesley Turner, MHM Georgia Power Company Timothy White, ECS The Boeing Company Gary Whittemore, CC The Boeing Company

Ameren Corporation Jeff Rehkemper, MHM Ameren Corporation Eric Rieke, PS Metamora Products Co.

David Widseth, CC The Boeing Company Ed Wilson, PM, IHM Kellogg Steve Wooten, MHM

Dean Rinehart, IHM Kellogg Alan Skaggs, S, PS Walt Disney Company

James Word, S, PS Walt Disney Company Christopher Wybert, MHM Ameren Corporation

Request more information at www.fluidpowerjournal.com

36 | September/October 2010

www.ifps.org | www.fluidpowerjournal.com

IFPS Certification Testing Locations

I

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

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

2. Submit your application with payment to IFPS Headquarters.

3. Upon receipt of your application, you will be e-mailed instructions. Testing dates for any locations listed below are as follows: September 2010 Tuesday, 9/7 Thursday, 9/16

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

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

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

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

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

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

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

Fullerton Community College Fullerton, CA

University of Delaware Newark, DE

University of Georgia Athens, GA

Richland Community College Decatur, IL

Irvine Valley College Irvine, CA

FLORIDA Brevard Community College Cocoa, FL

University of West Georgia Carrollton, GA

Rock Valley College Rockford, IL

Valdosta State University Valdosta, GA

University of Illinois at Urbana Champaign, IL

HAWAII BYU-Hawaii Laie, HI

Waubonsee Community College Grove, IL

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

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

Glendale Community College Glendale, AZ

COLORADO Community College of Aurora Aurora, CO

Mesa Community College Mesa, AZ

Community College of Denver Denver, CO

University of South Florida Tampa, FL

Northern Arizona University Flagstaff, AZ

Fort Lewis College Durango, CO

Valencia Community College Orlando, FL

Paradise Valley Community College Phoenix, AZ

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

Pima Community College Tucson, AZ

Pikes Peak Community College Colorado Springs, CO

GEORGIA Albany State University Albany, GA

Rio Salado College Tempe, AZ

Pueblo Community College Pueblo, CO

CALIFORNIA Allan Hancock College Santa Maria, CA

University of Colorado at Boulder Boulder, CO

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

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

Chapman University Orange, CA

DELAWARE Delaware State University Dover, DE

Foothill College Los Altos Hills, CA

Delaware Technical and Community College | Georgetown, DE

www.ifps.org | www.fluidpowerjournal.com

University of Florida Gainesville, FL

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

IOWA Hawkeye Community College Waterloo, IA University of Iowa Iowa City, IA Wartburg College Waverly, IA Western Iowa Community College Sioux City, IA IDAHO Boise State University Boise, ID Brigham Young University Rexburg, ID College of Southern Idaho Twin Falls, ID Eastern Idaho Technical College Idaho Falls, ID Lewis-Clark State College Lewiston, ID University of Idaho Moscow, ID ILLINOIS College of DuPage Glen Ellyn, IL

INDIANA Indiana Univ. Purdue University Indianapolis, IN Ivy Tech Community College/ Bloomington | Bloomington, IN Ivy Tech Community College/ Columbus | Columbus, IN Ivy Tech Community College/ Evansville | Evansville, IN Ivy Tech Community College/Gary Gary, IN Ivy Tech Community College/ Indianapolis | Indianapolis, IN Ivy Tech Community College/Kokomo Kokomo, IN Ivy Tech Community College/ Lafayette | Lafayette, IN Ivy Tech Community College/ Lawrenceburg | Lawrenceburg, IN Ivy Tech Community College/Madison Madison, IN Ivy Tech Community College/Muncie Muncie, IN Ivy Tech Community College/ Richmond | Richmond, IN

College of Lake County Grayslake, IL

Ivy Tech Community College/ Sellersburg | Sellersburg, IN

Illinois State University Normal, IL

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

John A. Logan Community College Carterville, IL

Ivy Tech Community College Terre Haute, IN

Lincoln Land Community College Springfield, IL

Purdue University West Lafayette, IN

Northern Illinois University De Kalb, IL

KANSAS Johnson County Community College Overland Park, KS

Parkland College Champaign, IL

Kansas State University Manhattan, KS

September/October 2010 | 37

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

MINNESOTA Minnesota State University, Mankato Mankato, MN

IFPS | International Fluid Power Society Raritan Valley Community College Somerville, NJ

HACC Gettysburg Campus Gettysburg, PA

Texas A&M University-Commerce Commerce, TX

University of Minnesota - Twin Cities Minneapolis, MN

NEW MEXICO Eastern New Mexico University Portales, NM

Harrisburg Area Community College Harrisburg, PA

Texas Tech University Lubbock, TX

University of Minnesota Morris, MN

San Juan College Farmington, NM

MISSOURI Avila University Kansas City, MO

NEVADA College of Southern Nevada Charleston Campus Las Vegas, NV

Metropolitan Community College-Penn Valley | Kansas City, MO

College of Southern Nevada Cheyenne Campus North Las Vegas, NV

University of Louisiana at Monroe Monroe, LA

Missouri Western State University St.Joseph, MO

Nicholls State University, Thibodaux, LA

Southeast Missouri State University Cape Girardeau, MO

College of Southern Nevada Green Valley Campus Henderson, NV

University of New Orleans New Orleans, LA

St. Charles Community College Cottleville, MO

College of Southern Nevada Henderson Campus, NV

MARYLAND Anne Arundel Community College Arnold, MD

State Fair Community College Sedalia, MO

NEW YORK Brooklyn College - CUNY Brooklyn, NY

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

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

Frederick Community College Frederick, MD

MISSISSIPPI Holmes Community College Goodman Campus | Goodman, MS

Harford Community College Bel Air, MD

Mississippi State University Mississippi State, MS

Hagerstown Community College Hagerstown, MD

University of Mississippi University, MS

Howard Community College Columbia, MD

MONTANA Montana State University Bozeman, MT

University of Maryland College Park, MD

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

VIRGINIA Old Dominion University Norfolk, VA

Austin Community College Austin, TX

Marian University of Fond du Lac Fond du Lac, WI

Collin Community College - Spring Creek Campus | Plano, TX

University of Wisconsin Oshkosh Oshkosh, WI

Eastfield College Mesquite, TX

University of Wisconsin-Milwaukee Milwaukee, WI

El Paso Community College El Paso, TX

UW-Green Bay Green Bay, WI

Clackamas Community College Oregon City, OR

Grayson County College Denison, TX

WYOMING University of Wyoming Laramie, WY

Mt. Hood Community College Gresham, OR

Lamar Institute of Technology Beaumont, TX

Portland Community College Rock Creek Portland, OR

Lamar University Beaumont, TX

Portland State University Portland, OR

Midwestern State University Wichita Falls, TX

RCC-SOU Higher Education Center Medford, OR

Sam Houston State University Huntsville, TX

Southwestern Oregon Community College | Coos Bay, OR

Southern Methodist University Dallas, TX

University of Oregon Eugene, OR

Texas A&M International University Laredo, TX

Ferris State University Big Rapids, MI

North Carolina Central University Durham, NC

University of Oklahoma Norman, OK

Henry Ford Community College Dearborn, MI

North Dakota State University Fargo, NC

Kalamazoo Valley Community College Kalamazoo, MI

The University of North Carolina Wilmington, NC

OREGON Central Oregon Community College Bend, OR

Lake Superior State University Sault Ste. Marie, MI

NORTH DAKOTA Bismarck State College Bismarck, ND

38 | September/October 2010

Middle Tennessee State University Murfreesboro, TN

Weber State University Ogden, UT

WISCONSIN Lakeshore Technical College Cleveland, WI

University of Central Oklahoma Edmond, OK

Mercer County Community College West Windsor, NJ

Utah Valley State College Orem, UT

TEXAS Abilene Christian University Abilene, TX

Mount Olive College Mount Olive, NC

Washtenaw Community College Ann Arbor, MI

Salt Lake Community College Salt Lake City, UT

Western Washington University Bellingham, WA

Delta College University Center, MI

Southwestern Michigan College Dowagiac, MI

Davis Applied Technology College Kaysville, UT

Walters State Community College Morristown, TN

Oklahoma State University-Tulsa Tulsa, OK

Gloucester County College Sewell, NJ

Trident Technical College Charleston, SC

UTAH Brigham Young University Provo, UT

South Seattle Community College Seattle, WA

Guilford Technical Community College Jamestown, NC

Schoolcraft College Livonia, MI

Technical College of the Lowcountry Beaufort, SC

Weatherford College Weatherford, TX

The University of Memphis Memphis, TN

MICHIGAN Baker College Online Flint, MI

NEW JERSEY Brookdale Community College Lincroft, NJ

Spartanburg Community College Spartanburg, SC

Victoria College Victoria, TX

Olympic College Bremerton, WA

Oklahoma State University Stillwater, OK

Southeast Community College Lincoln, NE

Piedmont Technical College Greenwood, SC

University of Texas El Paso El Paso, TX

Tennessee State University Nashville, TN

The University of Toledo Toledo, OH

Fayetteville State University Fayetteville, NC

Michigan State University East Lansing, MI

Orangeburg Calhoun Technical College Orangeburg, SC

University of Texas at Arlington Arlington, TX

WASHINGTON Central Washington University Ellensburg, WA

Boston, MA

Macomb Community College Warren, MI

University of Houston Houston, TX

Southern Adventist University Collegedale, TN

The Ohio State University Columbus, OH

OKLAHOMA Northern Oklahoma College Tonkawa, OK

NEBRASKA Bellevue University Bellevue, NE

Midlands Technical College Columbia, SC

TENNESSEE East Tennessee State University Johnson City, TN

NORTH CAROLINA East Carolina University Greenville, NC

Lansing Community College Lansing, MI

Horry-Georgetown Technical College Conway, SC

Franklin University Columbus, OH Rhodes State College Lima, OH

Tyler Jr. College Tyler, TX

University of Texas - Brownsville Brownsville, TX

SOUTH CAROLINA Coastal Carolina University Conway, SC

York Technical College Rock Hill, SC

University of Akron Akron, OH

University of Massachusetts

Harrisburg Area Community CollegeLancaster Campus | Lancaster, PA

Columbus State Community College Columbus, OH

The University of Montana Missoula, MT

MASSACHUSETTS North Shore Community College Danvers, MA

Harrisburg Area Community College York Campus | York, PA

PENNSYLVANIA Bucks County Community College Newtown, PA

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

Texas A&M University College Station, TX

www.ifps.org | www.fluidpowerjournal.com

CalendarofEvents

September/October 2010

OCTOBER 4 Pneumatic Specialist Online: 5 p.m. to 9 p.m.

CFC-Solar, Inc. Contact IFPS at 800-308-6005 4-8 2-day Basic 3-day Advanced Hydraulics Baltimore, MD CFC-Solar, Inc. Tel: 513-874-3225 www.cfc-solar.com 4-8 3- or 5-day Mobile Electric Class Cincinnati, OH CFC-Solar, Inc. Tel: 513-874-3225 www.cfc-solar.com 4-8 Introduction to Hydraulic Systems Milwaukee, WI MSOE Tel: 414-277-7269 www.msoe.edu 5 Hydraulic Specialist Online: 5 p.m. to 9 p.m.

CFC-Solar, Inc. Contact IFPS at 800-308-6005

6 Pneumatic Specialist Online: 5 p.m. to 9 p.m.

CFC-Solar, Inc. Contact IFPS at 800-308-6005 7 Hydraulic Specialist Online: 5 p.m. to 9 p.m.

CFC-Solar, Inc. Contact IFPS at 800-308-6005 11-13 Pneumatic Specialist with Test Cincinnati, OH CFC-Solar, Inc. Contact IFPS at 800-308-6005 11-14 Eaton Control F(x)™ Certification Maumee, OH Eaton Hydraulics Group Tel: 800-413-8809 http://web.fluidpower.eaton.com 11-15 Mobile Hydraulics Eden Prairie, MN Eaton Corporation Tel: 800-413-8809 http://web.fluidpower.eaton.com

Dichtomatik americas Looking for an opportunity to advance your sales skills while working in a fast paced environment?

Dichtomatik Americas is a rapidly growing industrial distributor of sealing products who is actively pursuing qualified candidates for PTD Territory Sales Manager positions located in Chicago, Indianapolis, Pittsburgh, and Philadelphia.

For consideration please email resume and salary requirements to hroiger@dichtomatik.us.

No phone calls please.

Equal Opportunity Employer.

12-14 Basic Pneumatic Technology Troy, MI Parker Hannifin Tel: 216-896-2577 www.parker.com/training 14-16 Hydraulic Specialist with Test Cincinnati, OH CFC-Solar, Inc. Contact IFPS at 800-308-6005 15 Control F(x)™ IEC 61131-3 Maumee, OH Eaton Hydraulics Group Tel: 800-413-8809 http://web.fluidpower.eaton.com 18-22 Electrohydraulic Feedback Systems Elyria, OH Parker Hannifin Tel: 216-896-2577 www.parker.com/training 18-22 Circuit Design Maumee, OH Eaton Hydraulics Group Tel: 800-413-8809 http://web.fluidpower.eaton.com

Classifieds

18-22 3- or 5-day Level 2 Mobile Hydraulics Cincinnati, OH CFC-Solar, Inc. Tel: 513-874-3225 www.cfc-solar.com 18-22 Hydraulic Systems Engineering Elyria, OH Parker Hannifin Tel: 216-896-2577 www.parker.com/training 18-22 Circuit Design Maumee, OH Eaton Corporation Tel: 800-413-8809 http://web.fluidpower.eaton.com

25-Nov 5 Industrial Hydraulics Maumee, OH Eaton Hydraulics Group Tel: 800-413-8809 http://web.fluidpower.eaton.com 26-28 Pump Controls Maumee, OH Eaton Corporation Tel: 800-413-8809 http://web.fluidpower.eaton.com 26-29 Mobile Hydraulic Milton, Ontario, Canada Parker Hannifin Tel: 905-693-4749 www.parker.com/training

25-27 Mobile Hydraulic Mechanic Hands-on Review Only Cincinnati, OH CFC-Solar, Inc. Contact IFPS at 800-308-6005 25-29 3- or 5-day Basic Industrial Hydraulics Cincinnati, OH CFC-Solar, Inc. Tel: 513-874-3225 www.cfc-solar.com

Serious About Surplus!

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

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

Bailey Surplus Serious About Surplus

www.baileynet.com

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

www.ifps.org | www.fluidpowerjournal.com

September/October 2010 | 39

Classifieds

September/October 2010

Wanted Growing, Chicago-area, master distributor of high-end Japanese hydraulic product line has an opportunity for a hydraulics engineer.

Technical expertise in hydraulics engineering as well as market and industry knowledge are required.

Compensation is commensurate with experience and qualifications. Some travel will be required. Please send applications to … hydraulicengineerjob@gmail.com CIL-MM1_CIL-MM1 7/2/10 11:11 AM Page 1

Company Page Air Logic....................................... 15 Air Logic....................................... 22 Allied Metrics................................ 25 Allied Metrics................................ 22 Argo-Hytos Inc.............................. 33 Argo-Hytos Inc.............................. 17 Argo-Hytos Inc.............................. 22 Attica Hydraulic Exchange Corp...... CIII Attica Hydraulic Exchange Corp.... 22 Behringer Fluid Systems................. 7 Behringer Fluid Systems............... 22 CEJN............................................... 8 CEJN............................................. 23 Clippard...................................... CIV Clippard........................................ 23 Cyber-Tech.................................... 10 Cyber-Tech.................................... 15 DELTA Computer Systems............ 23 Evonik Rohmax USA..................... 24 Evonik Rohmax USA....................... 5 ExpresSeal.................................... 23 ExpresSeal.................................... 24 Flaretite......................................... 10 Flaretite......................................... 16 Fluid Power Training Institute....... 29 Harvard Corporation..................... 11 Harvard Corporation..................... 16 Haskel International...................... 24 Hercules Sealing Products............ 14 Hercules Sealing Products............ 14 Hercules Sealing Products............ 14 Hercules Sealing Products............ 14 Hercules Sealing Products............ 14 Hercules Sealing Products............ 15 Hercules Sealing Products............ 24 Honor Pumps................................ 13 Honor Pumps................................ 17 IFPE................................................ 3 Inserta........................................... 25

Company Page Inserta........................................... 15 Inserta........................................... 15 La-Man.......................................... 23 La-Man.......................................... 24 Lightning Hybrids......................... 11 Lightning Hybrids......................... 24 Main Manufacturing...................... 18 Main Manufacturing...................... 25 Marzocchi Pumps......................... 25 OILMISER....................................... 9 OILMISER..................................... 16 Oil-Rite.......................................... 25 Parker Hannifin Corp.

Racor Div...................................... 27 Parker Hannifin Corp.

Racor Div...................................... 26 Peninsular Cylinder Co.................. 36 Peninsular Cylinder Co.................. 18 Power Valve.................................. 34 Power Valve.................................. 17 Safeway Hydraulics Inc................. 34 Spectronics Corp.......................... 21 Sunfab.......................................... 27 Super Swivels............................... 26 Ultra Clean.................................... 31 Webster Instruments.................... 31 Webster Instruments.................... 16 Western Fluidyne..........................CII Western Fluidyne.......................... 17 Western Fluidyne.......................... 26 Yates Industries.............................. 1 Yates Industries............................ 16 Yates Industries............................ 26 Youli.............................................. 17 Youli.............................................. 29 Young Powertech.......................... 18 Young Powertech.......................... 26 Zinga Industries............................ 26

Ad • Product Spotlight • Literature Review

Push-Quick Fittings

TECHNICAL SALES POSITION Work with a long standing International manufacturer of hydraulic pumps and motors in an organization that allows you the freedom to develop and grow a new customer base.

This is an exciting position that will give the opportunity to travel extensively throughout North America. Previous experience and mechanical aptitude required. Fluid Power technical degree and IFPS certification are a plus. If you have excellent people skills and are customer service oriented this could be the position for you. This position provides a competitive salary and benefit package based on previous experience.

FPJ5.1.08:Layout 1

5/8/08

3:34 PM

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

Pag

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If interested in this position, please e-mail cover letter, resume, and salary requirements to recruitment@rotarypower.com.

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SURPLUS CENTER

1015 West O Street, Lincoln, NE 68528 Contact Our Buyers Phone 402-474-4055 Fax 402-474-5198 email buyer@surpluscenter.com www.surpluscenter.com Buying and Selling Surplus Since 1933

36

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