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September/October 2016

www.FluidPowerJournal.com

Reduce Downtime on p.34

C I T S O N G A I D EQ UIPMENT TEST

PLUS Fire-Resistant Hydraulic Fluids:

NG MACHINES TI T U C T E -J R TE FOR WA

AND MORE!

COST vs. BENEFITS

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CIRCLE 413


In This Issue S E P T E M B E R / O C TO B E R 2 0 16

• VO L U M E 2 3

ISSUE 8

47 8 Electronic Controls Specialist (ECS) CERTIFICATION

34

12

DEPARTMENTS

Asset Utilization: The Key to a More Efficient Operation

4 NOTABLE WORDS

6 FIGURE IT OUT

26

Operations, maintenance, and fleet managers

10 SAFETY FOCUS

CONTAMINATION CONTROL SYSTEM Does the Dirty Work

need a thorough understanding of how their

16 IFPS EXECUTIVE PROFILE

assets are being utilized to find new ways to

17 INTERNATIONAL COVERAGE

18 PRODUCT SPOTLIGHT

25 CALENDAR OF EVENTS

28 IFPS UPDATES

36 FPEF UPDATES

37 LITERATURE REVIEW

Many manufacturers are experiencing

43 NFPA UPDATES

a weakened economic environment. So

48 INTRODUCTION TO

discussions on spending more on anything,

HYDRAULICS FOR INDUSTRY

including fire-resistant hydraulic fluids, are

PROFESSIONALS

usually not at the top of anyone’s list…unless

51 ECONOMIC REPORT

there is a fire.

54 CLASSIFIEDS

33 How to Handle COMPLEX LUBRICATION ISSUES

34 Diagnostic TEST EQUIPMENT

40 FLOW MEANS "GO" ...Well, Not Exactly

improve productivity and lower costs.

52

Fire-Resistant Hydraulic Fluids: Cost vs. Benefits

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

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CIRCLE 414


NOTABLE WORDS

Energy Efficient

Hydraulics & Pneumatics Conference Returns in 2017 By Dean Houdeshell, PE, CFPAI/AJPP, CFPE, CFPS, CFPIHT, CFPMHT, CFPMHM, Cemen Tech Inc., 2016 IFPS Vice President of Education

Efficient consumption of energy is one of the key concerns around the world today. In fact, my local power company regularly prepares a report so I know how my household energy consumption compares with other households in the neighborhood. I think this is great, because it creates an awareness of something I might have not given much thought to otherwise. It has also started to change my behavior; I now wash my clothes in cold water, make sure all computers use the powersaving modes, and close the shades to keep the heat out in the summer. This all adds up to energy savings. In a similar way, the Energy Efficient Hydraulics & Pneumatics Conference (EEHPC) was established not just to create awareness, but also to engage fluid power professionals to take action by sharing best practices, cutting-edge technologies, and success stories. Over the past year, I have had the privilege to work with 20 fluid power professionals from across the industry to develop the upcoming conference that will be co-located with IFPE 2017 in Las Vegas from March 8-10. A lot of effort has been put forth to make next year’s conference a great one, and there is a lot of passion around this event. I would like to thank the following companies that participated: MTS Systems Corp.; Moog Industrial Group; Enfield Technologies; SMC Corp. of America; Festo Corp.; Bosch Rexroth Corp.; Poclain Hydraulics, Inc.; Parker Hannifin; Quality Filtration, LLC; Ross Controls; Curtiss-Wright; Bimba Manufacturing Co.; and Eaton, as well as members from the IFPS, the FPDA Motion and Control Network, NFPA, and the Association of Equipment Manufacturers (AEM). The EEHPC Planning Committee was split into two subcommittees: hydraulics and pneumatics. Each subcommittee then developed the program of technical sessions and recruited speakers to participate. The time and effort the subcommittee put into this conference was outstanding. It is always great to see the dedication of people in fluid power who, regardless of the logo on their shirt, come together for the greater cause of the industry. Changing technologies continue to drive improvements across the industry. Component manufacturers continue to make improvements to their products. System integrators are looking at ways to maximize efficiency by selecting the right components and optimizing the way they are connected. With increasing use of electronics in fluid power systems, smart technologies are being used to create smarter, more efficient fluid power systems. Over 20 experts from the industry will share ideas and engage in discussions with the audience. The three-day conference kicks off with a keynote success story from Eaton, followed by topics related to smart system design and assessing systems for efficiency improvements. The second day begins with a keynote presentation from Danfoss on innovations in fluid power and continues with topics related to applied energy efficiency. The conference wraps up on the third day with a glimpse into the future. The keynote presentation will address opportunities and challenges in miniaturized fluid power technologies and follow with a presentation on how those challenges are being addressed. You won’t want to miss this conference. It has something for everyone and provides you with access to top experts in the fluid power industry. You’ll also have an opportunity to discover the latest energy-efficient technologies, as well as network with other fluid power professionals. You’ll go away with a better understanding of what’s happening, what’s possible, and where you can make a difference in the future of fluid power. I look forward to seeing you there!

4

www.FluidPowerJournal.com • September/October 2016 • www.IFPS.org

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 Founders: Paul and Lisa Prass Associate Publisher: Marc Mitchell Editor: Kristine Coblitz Technical Editor: Dan Helgerson, CFPAI/AJPP, CFPS, CFPECS, CFPSD, CFPMT, CFPCC - CFPSOS LLC Account Executive: Bob McKinney Art Director: Quynh Vo Director of Creative Services: Erica Montes Accounting: Donna Bachman, Debbie Clune Digital Strategy Manager: Jeff Maile Publishing Assistant: Sharron Sandmaier Circulation Manager: Andrea Karges

INTERNATIONAL FLUID POWER SOCIETY 1930 East Marlton Pike, Suite A-2, Cherry Hill, NJ 08003-2141 Tel: 856-489-8983 • Fax: 856-424-9248 Email: AskUs@ifps.org • Web: www.ifps.org 2016 BOARD OF DIRECTORS President & Chairperson Rance Herren, CFPSD, CFPECS, CFPMT, CFPAI - National Oilwell Varco Immediate Past President Marti Wendel, CFPE, CFPS, CFPCC - Curtiss Wright Sprague Division First Vice President Richard Bullers, CFPPS - SMC Corporation of America Vice President Education Dean Houdeshell, PE, CFPAI, CFPE, CFPS, CFPIHT, CFPMHT, CFPMHM - Cemen Tech Inc. Treasurer Jeff Kenney, CFPIHM, CFPMHM, CFPMHT - Coastal Hydraulics, Inc. Vice President Membership & Chapter Support Bill Jordan, CFPAI/AJPP, CFPMHM, CFPMHT - Altec Industries, Inc. Vice President Certification Timothy White, CFPAI/AJPP, CFPS, CFPECS, CFPMIH, CFPMMH, CFPMIP, CFPMT, CFPMM - The Boeing Company Vice President Marketing & Public Relations Scott Nagro, CFPS - HydraForce, Inc. Vice President Educational Foundation Randall Smith, CFPHS - Northrop Grumman Corp. DIRECTORS-AT-LARGE Randy Bobbitt, CFPS - Danfoss Power Solutions Kenneth Dulinski, CFPAI/AJPP, CFPECS, CFPHS, CFPMIH, CFMMH Macomb County College Jose Garcia, CFPHS - Purdue University Jeff Hodges, CFPAI/AJPP, CFPMHM - Altec Industries, Inc. John Juhasz, CFPECS, CFPS - Kraft Fluid Systems, Inc. Sam Kaye, CFPS, CFPMT, CFPMM, CFPMMH, CFPMIP, CFPMIH Ensign Drilling Rocky Phoenix, CFPMHM - Open Loop Energy Denis Poirier, Jr., CFPAI/AJPP, CFPCC, CFPIHM Eaton Corporation, Hydraulics Group Robert Post, CFPHS - Bailey Hydraulics Bishwajit Ranjan, PE, CFPE, CFPS - Ellwood Texas Forge Houston Scott Sardina, PE, CFPHS - Controlled Fluids, Inc. HONORARY DIRECTORS John Groot Robert Sheaf, CFPAI/AJPP, CFPE, CFPS, CFPECS, CFPMT, CFPMIP, CFPMMH, CFPMIH, CFPMM IFPS STAFF Executive Director: Donna Pollander, ACA Communications Manager: Adele Kayser Client Data Manager: Sue Dyson Business Development Manager: Jeffrey Morrow Assistant Director: Jeana Hoffman Certification Coordinator: Susan Apostle Bookkeeper: Diane McMahon Administrative Assistant: Beth Borodziuk 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 180457118. All Rights Reserved. Reproduction in whole or in part of any material in this publication is acceptable with credit. Publishers assume no liability for any information published. We reserve the right to accept or reject all advertising material and will not guarantee the return or safety of unsolicited art, photographs or manuscripts.


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www.IFPS.org • September/October 2016 • www.FluidPowerJournal.com CIRCLE 415

5


FIGURE IT OUT 5" BORE x 3.5"R x 36" LONG

5" BORE x 3.5" R x 36" LONG

Gear Pump Load Sense A hydraulic distributor hired a sales engineer for a new territory they were moving into. The first customer the engineer visited requested a quote on a hydraulic system. The customer provided the following requirements to press two large forgings together:

PB PB

ƒƒ 5” bore cylinder with a 3.5” rod, 36” long ƒƒ DCV, 3-position with a return “kick back to center” feature, manually operated ƒƒ Flow controls on both cylinder ports ƒƒ Return line filtration ƒƒ A pump that delivered 30 gpm at 2450 psi (not piston-type) ƒƒ No heat exchanger, if possible (The customer was going to build a larger reservoir than normal.) ƒƒ Electric motor had to be 230 volt, 3-phase, 60-cycle, C-face with coupling assembly. ƒƒ All parts needed to ship loose for the customer to mount and plumb on his machine. The sales engineer designed the circuit and quoted the customer a price to deliver all of the components. The customer installed the parts using the circuit supplied. The sales engineer then got a call from the customer stating that the gear pump was overheating. It also seemed as if the load sense worked when retracting, but when extending at no load, was always at 2450-psi system pressure. The return line screw-on filter element was coming loose, and the customer had to keep tightening it.

SET SET @ @ 2450 PSI 2450 PSI

Any idea what's causing the problems?

SET @

SET @ 200PSI 200LSPSI LS 30 30 GPM GPM

EM EM

45 GPM GPM RATED 45 RATED 3M FILTER 3M FILTER

GPMLOAD W/ LOAD 30 GPM30W/ CONTROL SENSE SENSE CONTROL

Previous Problem

AERATED OIL ON A LOG SPLITTER Any idea what the problem could be?

I loaned my log splitter to a friend whose tree fell after a storm. The tree was a blue spruce evergreen about 30-ft. tall. It surprised me that the tree’s root system, after 20 years of growth, barely penetrated the ground but seemed to be spread out over a 10 to 12-ft. radius being only about 2 to 6-in. deep. He had cut the tree up in short lengths that would fit into his free-standing fireplace and needed to split and stack the logs. He borrowed my splitter and complained that it slowed down when splitting the logs—slower than it had when he helped me in the past. I explained to him that the splitter had a “Hi-Low” pump system with a new cylinder and that it would slow down when it encountered logs that needed pressures higher than 600 psi (see the circuit). He felt this wasn’t the problem, so I went over to his house and looked at the splitter. He was correct; the splitter encountered the log, slowed down, but eventually split the log. I was sure it was the pump failing, but without a gage or flow meter I removed the pump and took it to my shop for testing. To my surprise, the pump tested out just fine.

Solution The log splitter problem of taking too much time to pressurize and slowing down the cycle time was caused by the oil having excess air mixed with it. The return line was returning oil above the fluid level, aerating the oil. The air slowed down the ability of the oil to pressurize quickly. Filling the tank frame with more oil solved the problem.

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

6

www.FluidPowerJournal.com • September/October 2016 • www.IFPS.org


CIRCLE 416


ELECTRONIC CONTROLS SPECIALIST

(ECS)

If you currently hold an IFPS Hydraulic Specialist, Pneumatic Specialist and/or Specialist certification, the ECS is a perfect complementary certification for you to obtain. Our newly revised study manual not only helps you prepare for the certification, but it is also a stand-alone reference guide. It contains vital and practical information on best practices for anyone responsible for designing, analyzing, or selecting components for the electronic control of fluid power systems.

Electronic Control Specialist Certification Study Manual • Critical material to study for the Certification test • Review questions at end of each chapter • Test your knowledge with pre-test questions

CERTIFICATION OUTLINE ELECTRONIC AND ELECTRICAL PRINCIPLES

ƒƒ Read and interpret fluid power schematics ƒƒ Perform calculations that describe the motion and force of fluid power actuators ƒƒ Demonstrate an understanding of friction and leakage in fluid power components and their effects on system performance ƒƒ Identify the causes and minimize the effects of hydraulic shock in a system ƒƒ Demonstrate knowledge of the operation and application of proportional valves ƒƒ Describe the operation and application of electric flow control devices ƒƒ Describe the operation and application of electric pressure control devices ƒƒ Demonstrate a knowledge of the effects of pressurecompensated components on control systems ƒƒ Demonstrate knowledge of the operation and the application of servo valves ƒƒ Demonstrate knowledge of the effects of mechanical nulling on control systems

8

ƒƒ Basic Electrical Quantities and Measurements ƒƒ Inductance/Capacitance ƒƒ Block Diagrams ƒƒ Power Supply ƒƒ Circuit Protection ƒƒ NEC Wiring Considerations ƒƒ Power and Signal Quality ƒƒ Grounding Job Responsibility INPUT/OUTPUT DEVICES

ƒƒ Switches ƒƒ Input Potentiometers and Joysticks ƒƒ Sensors ƒƒ Application of Sensors ƒƒ Sensor Sinking, Sourcing and Wiring ƒƒ Understanding Encoders, Linear Sensors, and Transducers and Joysticks ƒƒ Solenoids ƒƒ Operating Environmental Considerations Job Responsibility APPLYING CONTROL THEORY

ƒƒ Determine Hydraulic Stiffness of a System ƒƒ Determine Actuator Natural Frequency ƒƒ Describe Frequency Response of a System ƒƒ Interpret Bode Diagrams

www.FluidPowerJournal.com • September/October 2016 • www.IFPS.org

FL

Job Responsibility

FLUID POWER SYSTEMS

ER

Job Responsibility

D POW UI

INTERNATIONAL

SO

CIETY

12/15/15

Education • Certification • Profe ssionalism P.O. Box 1420, Cherry Hill, NJ 08034 P 800-308-6005 • E askus@ifps.org • www.ifps.org

ƒƒ Identify General Control System Design ƒƒ Understand Control Techniques Used in Fluid Power Systems ƒƒ Interpret and Create Block Diagram ƒƒ Evaluate Basic System Physics ƒƒ Discuss the Effect of PID Loop Tuning on a Fluid Power System Job Responsibility INTERACTING WITH CONTROLLERS

ƒƒ Select Controller Architecture ƒƒ Specify Controller Performance Parameters ƒƒ Select Controller Interface Hardware ƒƒ Understand IEC 61131-3 Logic Programming ƒƒ Recognize Common Program Solutions

ƒƒ Trace and Influence Data Job Responsibility UTILIZE INDUSTRIAL NETWORKS

ƒƒ Open System Interconnect Model ƒƒ Select Network Architecture and Components ƒƒ Network Implementation Considerations ƒƒ Wireless Networking in Fluid Power ƒƒ Human Machine Interfacing

VISIT

www.ifps.org/specialist to learn more and to test your skills with online pretest questions.


CIRCLE 417


SAFETY FOCUS

Are You Competent When it Comes to Safety? By Carl Potter, CSP, CMC

Imagine a worksite where everyone takes responsibility for hazard recognition and control.”

Competency – it’s a word we hear bantered about when we discuss a worker’s knowledge, skills, and aptitude with regard to safety. Have you ever wondered what it would be like to have a fully competent workforce, where every person was fully capable of performing work safely? Some might say that’s Utopia. (The word utopia means “no-place” or “non-existent place”; in other words, they might say there’s no possibility of having a workplace where everyone is proficient in knowing and applying safety rules, practices, and procedures.) It’s a challenge worth taking up, wouldn’t you agree?

Toward a More Competent Workforce Competency is absolutely required as part of a sustainable safety culture. Developing a strong safety culture where competency is a foundation requires commitment to build understanding, promote application, and instill motivation. The commitment must come from leadership for

10

focus and resources—both time and money. While many executives tend to be more comfortable with spreadsheets, balance sheets, and the like than they are with safety processes and procedures, they have a responsibility to oversee the safety of the employees and contractors that work for the organization. Part of that responsibility is ensuring the organization has safety-competent personnel. Executive and leadership commitment is only half of the equation. Building a safety-competent workforce also requires employee commitment. Leaders can provide time and money for employee training and development to build knowledge and skills that will keep people safe—formal and on-thejob. However, learning and application can’t be forced. Employees must be engaged in learning and application.

Who is the Safety-Competent Person? Have you asked yourself who the safety-competent persons are at your work site? If not, you

www.FluidPowerJournal.com • September/October 2016 • www.IFPS.org

should. Competency is based on knowledge and experience of the people assigned to do specific work, which gives them the ability to recognize hazards and the authority to mitigate the hazard. Consider OSHA’s definition: Under OSHA, General Safety and Health Provisions, Construction, Definitions (1926.32(f ): “One who is capable of identifying existing and predictable hazards in the surroundings or working conditions which are unsanitary, hazardous, or dangerous to employees, and who has authorization to take prompt corrective measures to eliminate them. If you are a supervisor, manager, or executive at your worksite, you must know who the competent personnel are. First of all, it’s essential to have identified safety-competent personnel and ensure that they remain competent for the work for which they are responsible. Second, during the investigation of a serious injury or fatality, an OSHA inspector will likely ask organizational leaders to identify the safety-competent people.


The company leaders have an obligation to know these competent people—not just the company safety manager or the person designated as “in charge of safety.” No one person can know all there is to know about every aspect of safety in the organization; in other words, no one can be expected to be the overall safety-competent person. Hence, during an investigation, company leaders may find it difficult to make a case for the safety manager being safety competent. OSHA compliance officers will be quick to tell you that not everyone meets the “competent person” designation. Creating competency in safety is a journey that must begin with basic understanding, application, and motivation to know and do the work without injury to self and others. General safety courses, such as the OSHA 10-hour and 20-hour courses, are good for general education but do not deeply address areas where competency is required. Here are a few areas where safety competence must be specific:

ƒƒ provide sufficient training so employees know how to apply the safe work procedures to their specific work, and ƒƒ motivate employees to take responsibility and be accountable for safety throughout the organization. Each of these actions can mean that your workplace, shop, or work site is one where it’s difficult to get hurt. And that means more people will go home to their families every day without injury.

CARL POTTER is a certified safety professional and certified management consultant who writes, speaks, and consults with leaders who want to create a zero-injury workplace. Since 1992, he has worked across the U.S. and Canada with one purpose – to eliminate every workplace injury. Learn more about his Hazard Recognition and Control Workshop at www.safetyinstitute.com or contact him at carl@safetyinstitute.com.

Electrical Work Scaffolding Excavation Hazardous Material Machine Guarding Other (as designated by your own worksite hazard assessment and industry standards)

A worksite assessment will help you to identify the specific safety competencies that are required. This is a process that should be undertaken as part of your safety management process (SMP) and create an organizational standard to be developed and maintained. When it comes to safety competency, organizations must be specific; however, all employees at every level (from the CEO through the college intern) need to be trained to recognize hazards of all types. According to OSHA’s General Duty Clause (the most-cited regulation), the employer must mitigate all recognized hazards.  The first step to mitigation of hazards is recognition. The second step is to make sure employees can evaluate the risk level and then apply controls.  Do your part as a leader in your organization to ƒƒ ensure that everyone understands their role with regard to specific skills and general hazard recognition and control, CIRCLE 418

www.IFPS.org • September/October 2016 • www.FluidPowerJournal.com

11


ASSET UTILIZATION: THE KEY TO A MORE EFFICIENT OPERATION By Jeffrey Morrow, International Fluid Power Society

T

oday’s competitive business climate requires leaner companies. Gone are the days of unlimited budgets and surplus staffing. Rather, every aspect of operation is scrutinized for ways to heighten efficiency and eliminate waste. Moreover, this scrutiny is relentless: its goal is continuous improvement, not only in production speeds and the bottom line, but also in product quality and customer service. For Transportation and Logistics, this kind of efficiency analysis is especially crucial. Operations, maintenance, and fleet managers need a thorough understanding of how their assets are being utilized to find new ways to improve productivity and lower costs.

WHAT, EXACTLY, IS ASSET UTILIZATION? Asset Utilization (AU) is a metric—a number—that helps managers figure out how to improve their bottom lines by making better use of their company’s assets. Depending on the type of company, assets might be any num-

12

ber of things—such as equipment, real estate, finances, and/or paid personnel. An AU calculation is simple. For an entire company, the AU ratio is the total company annual revenue (for example, $500,000) divided by the total value of its assets (for example, $1,000,000). This percentage reflects how much “bang for the buck” a company receives from its resources. In this case, the company’s AU ratio is 0.50, or 50%. A metric like this can be used to follow a company’s progress over time—the obvious goal being to raise this percentage. Frequently, managers will look at the AU of separate business units or other functions within the company to better understand which parts are working efficiently and where changes need to be made.

ASSET UTILIZATION AS APPLIED TO FLEET MANAGEMENT If AU is Revenue

___________

Asset Value

www.FluidPowerJournal.com • September/October 2016 • www.IFPS.org

there are two ways to increase it: either increase the revenue or decrease the value of the assets.

How can a fleet manager increase a company’s revenue? There are several ways. The most obvious method is by cutting operating costs, such as by improving preventive maintenance practices, spending less time and money on repairs, or by decreasing inventory. The fleet might also generate revenue over time by improving customer satisfaction. Employee satisfaction affects revenue, too. Happy employees will deliver better customer service, perform better overall, waste less time, and be more likely to stay with the company. Employee retention means more experienced, efficient personnel who deliver better customer service. Better retention also decreases the amount of time wasted on hiring and training new employees. As for the bottom half of the equation, a fleet’s asset value may be lowered in a number of ways, such as by maintaining fewer vehicles and by housing a smaller inventory of spare parts. Fewer vehicles will also require less real estate in which to house and repair them, as well as less insurance. AU-improving modifications like these create tangible results, new efficiencies, and a positive ripple effect across many departments.


SURRENDERING THE FLEET MEANS LOSING CONTROL OF AU Some companies outsource fleet management. Although allowing another entity to take over this responsibility may be convenient, it is likely deleterious to the bottom line. Once decisions regarding the fleet are being made out-of-house, there is no way to systematically improve performance or reduce waste. In short, a great opportunity to better the bottom line has been lost. Furthermore, if a vehicle breaks down, the outsourced company will fix it and charge accordingly—a poor incentive to improve performance. Even companies that do hire outside fleet management, though, might be advised to maintain a number of welltrained employees who can oversee the inventory and evaluate the outsourced service.

of Fleet Management Services for Montgomery County, Md., earned the General Motors-sponsored Fleet Manager of the Year award by implementing a comprehensive utilization plan. As a result of one of his strategies—ramping up training and preventive maintenance programs—downtime decreased 20%, technician productivity rose above 85%, and overall maintenance cost per mile decreased 8%. In another component of his plan, a focus on promoting safety reduced on-the-job, losttime injuries by 33%.

MECHANIC SKILL LEVEL HAS A DIRECT EFFECT ON RELIABILITY Knowledge is crucial, and ensuring that employees have all the skills they need to perform effectively is paramount. Many U.S.trained mechanics have already been certified through the Automotive Service Excellence (ASE) system. However, ASE testing doesn’t cover hydraulics, which is a key element for the utility industry. This proficiency gap poses a significant problem and results in excessive

IT’S TIME TO GEAR UP

HOW COMPANIES ARE APPLYING EFFICIENCY ANALYSIS TO MANAGE THEIR FLEETS To track fleet activities, many companies are applying new telematics-tracking and data-collection methods. These GPS-type systems can transmit or record anything from vehicle location to engine status to fuel use to driver behavior. Associated software can be used to organize the data for easy interpretation. Evaluation of such knowledge gained by monitoring fleet activity over several months often reveals trends that suggest solutions most likely to improve efficiency. A metric such as the number of days, miles, or engine hours between breakdowns can be useful for calculating efficiency and understanding how much downtime and repair work vehicles have been requiring over a given period. Careful examination of this data is the best way to learn what changes will make the most difference to asset utilization.

VEHICLE RELIABILITY IS KEY One of the most cost-effective ways to increase fleet profitability is by eliminating the causes of lost efficiency. Increasing reliability, that is, decreasing time in the shop, of the vehicles on hand means both decreased assets, as fewer vehicles will be needed, and cost savings—both of which will help to raise the AU percentage. The chief way to achieve better reliability is through better preventive maintenance. Not only does this strategy decrease downtime, but better preventive maintenance also contributes to lower costs. Avoiding major repairs as much as possible diminishes the need for costly spare parts or entire unit replacements, lessens the number of mechanic hours expended, and decreases the time it takes to get the vehicle back on the road. Acting on AU analysis can achieve impressive results. According to a July 2015 Government Fleet article, Bill Griffiths, division chief

You Spoke and We Listened – Our Gear Pumps Are Better Than Ever Metaris took your valuable feedback and ran with it. We’ve made enhancements to our gear pump line based on that feedback–improving quality, improving service, and providing greater availability. We are committed to the process of continuous improvement that will bring you the best possible product every time you order. Whether it’s to get your machine back up and running or to stock your shelves–we’ve got you covered. Oh, and be on the lookout in the coming months for more announcements and promotions to our gear product line. To learn more, give us a call or visit us at METARIS.cOM

1-800-238-0155 sales@metaris.com

www.metaris.com CIRCLE 419

www.IFPS.org • September/October 2016 • www.FluidPowerJournal.com

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time in the shop, as people directly involved in fleet management well know. “Over 44 years in the business, I’ve supervised multiple shops and professionally observed scores of technicians,” said the award-winning equipment manager for one of the largest U.S. state departments of transportation. “The typical technician, usually hired from a car or truck dealership, has no clue about hydraulics. All they can do is guess wrong components one after the other, replacing each until they find the part that is damaged. And maybe they could have fixed the entire problem by adjusting a valve somewhere.” Joey Clemmons, CFPAI, CFPIHM, CFPS, a former fluid power component company salesman who saw an opportunity to fill a niche as an independent fluid power instructor, agrees. “There is a void in the educational realm,” he said. “Unless they have a Mechanical Engineering degree, guys don’t even know the symbols used to describe the circuits in hydraulics. They can’t figure out how the machine works, let alone how to fix it. For instance,” he said, echoing the equipment manager, “someone who doesn’t know any better might opt to replace a malfunctioning pump, where an IFPS-certified mechanic might simply fix it by adjusting a release valve.”

IFPS AS THE HYDRAULICS EQUIVALENT TO ASE Clemmons considers the nationally recognized International Fluid Power Society (IFPS) certification equivalent to ASE mechanic certification. So does the director of fleet services at a major telecommunications company, who says, “IFPS is the fluid power equivalent to ASE from the standpoint of safety in both using and repairing hydraulics equipment and of improv-

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www.FluidPowerJournal.com • September/October 2016 • www.IFPS.org

ing asset availability by fixing it right the first time, making it safe and getting it back out on the road.” He adds, “Hydraulically driven equipment comes with a lot of liability. I drive home the safety culture: you’re not just fixing a switch; you’re responsible for somebody’s life, maybe.” But why does the subject of hydraulics require its own test? “Most non-technical people think hydraulics is as simple as the water pipes in your house. They don’t understand the complexity of modern hydraulic systems,” the equipment manager explains. “In my state’s DOT, a handful of techs assigned to an area have to be able to service hundreds of different brands and types of equipment, from snow blowers to complex dirt-moving machinery. These techs have to be really good at what they do. For instance, an excavator is a very sophisticated piece of hydraulic equipment with thousands of pieces and wiring that looks like spaghetti. Mechanics need to know how to diagnose—insert flow meters and pressure gauges into the system to see where the problem is; they need to understand open, closed, and hydrostatic systems.” One way of ensuring that technicians are truly competent in hydraulics is via certification and training with the help of the IFPS.

PROPERLY TRAINED MECHANICS LOWER COST AND REDUCE LIABILITY While certification and training are not free, in the case of hydraulics, the return on investment (ROI) is seen as significant. “As a manager,” says the telecommunications fleet director, “one of your tools for achieving peak performance is empowering the people who work for you. The payoff of IFPS certification is in repair cycle times—techs come to understand the schematics, the symbology, how the equipment works. Over 6-8 months, we began to see a turnaround as we adopted this in more facilities. I’ve saved millions of dollars by having my people trained and certified.” Less equipment downtime and a drastic decrease in parts and replacement expenditures through better preventive maintenance and effective troubleshooting are the primary benefits of improving technician skill levels in hydraulics. “It’s hard to precisely measure the ROI of training and certification because there are too many variables—the age of the equipment, weather conditions, etc.,” says the DOT equipment manager. “But I guarantee, not having technicians who understand hydraulics wastes a ton of time and money.” Beyond saving time and money, efficient problem solving, greater skill, and proper maintenance also result in safer operation. Prompt, high-quality repairs and the right preventive maintenance at the right time can prevent damage to equipment and unsafe conditions that may result in injury days lost and higher liability costs.


Mark Perry, CFPHS, sales manager at Fitzsimmons Hydraulics, says, “Passing an IFPS test turns a light on, that there is a proper way to do things. It makes employees think safer and more productively.” Perry believes hydraulics certification is a great separator. “Trained employees know what to look for if a machine goes down, troubleshoot fast, and have it back up and running right away. They do it right the first time because they understand the logic—how the machine is supposed to work.” He feels that properly trained employees promote efficient operations. “When managers complain about increasing costs,” Perry says, “the audit invariably trails back to a lack of training, leading to excess expenditures.” Beyond implied reliability and safety, well-maintained vehicles are more environmentally friendly. This can mean savings from greater fuel efficiency and also better customer satisfaction due to cleaner emissions, less leakage of hazardous fluids, and so on.

AU FOR FLEET MEANS UPGRADING RELIABILITY—AND BETTER-TRAINED MECHANICS OFTEN MAKE THE DIFFERENCE

making sure mechanics have all the skills they need. One skill set often lacking is hydraulics repair. Upgrades in hydraulics training and certification can make a significant impact on fleet Asset Utilization and hence, profitability.

Implementing as asset utilization program means making gradual improvements over time with the goal of having a fleet operate as close to maximum capacity as possible, every day. For fleet managers, this essentially means maximizing reliability. An important way to do this is by

FOR MORE INFORMATION Jeffrey Morrow is business development manager for the IFPS. He can be reached at jmorrow@ifps.org or at www.ifps.org.

EFFECTIVE TESTING AND CERTIFICATION HELP ENSURE MECHANIC COMPETENCE—AND RETENTION Managers who want to raise the skills of their mechanics can avail themselves of specific testing and certification programs, such as those offered by the IFPS. One reason IFPS certification is so well respected is that the actual tests are extremely well crafted. “Training’s not enough; you need to make sure the learning happened,” says the DOT equipment manager. “IFPS exams include both written and hands-on practical, timed assessments. You can be sure an IFPS-certified tech really does know the material.” Jon Jensen, CFPAI, CFPECS,CFPPS, is energy conservation group manager at SMC Corporation of America. SMC, a Japanese pneumatic technology company, required fluid power certification for all its technicians, and Jensen had to make it happen. “IFPS was really the only game in town,” he says. The test was harder than expected. “They really do their due diligence to provide quality assessment tools based on industry best practices, vetted by subject matter experts and validated by testing experts. This certification indicates a significant level of competence, and after passing it, employees seem to have a sense of accomplishment and feel more empowered and confident in their work.” This kind of positive employee response to IFPS testing and training is typical. People who go through certification experience better job satisfaction because they take pride in knowing they are capable of doing excellent work. They also understand that by adding skills, they are making themselves more attractive in the job market. Even so, these employees are more likely to stay because they feel valued by their company, especially with the prospect of going back and obtaining even higher levels of certification. CIRCLE 421

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IFPS EXECUTIVE PROFILE

Denis M. Poirier, Jr. Denis M. Poirier Jr., CFPAI/AJPP, CFPCC, CFPIHM, is senior training specialist at Eaton Hydraulics Group Training Services and provides detailed technical training to professionals in the hydraulics industry. He conducts sessions in the area of industrial hydraulics, mobile hydraulics, troubleshooting, electro-hydraulics, and Eaton-specific products. He is a member of the 2016 IFPS Board of Directors.

Q

How did you begin your career in the fluid power industry?

I took my first technical course in hydraulics and electro-mechanical maintenance in 1989 while serving on active duty in the United States Navy. As a young sailor working in the ordnance field, I was afforded a very up-close and personal understanding of the true power of hydraulics. Over the next 22 years, I was able to refine my maintenance skills and ultimately put that experience to work as a military instructor teaching similar courses I had attended earlier in my naval career. The transfer from active duty military to industrial maintenance, management, and ultimately to the position as a senior training specialist with Eaton’s Hydraulics Group was a natural transition for me. When I consider the long relationship I have had with fluid power and mechanized equipment, I can’t imagine working in any other industry.

Q

Why did you decide to pursue IFPS certification?

I am a strong proponent of lifelong learning. Whether it is through certification, technical training, or academia, continual education is a key part in maintaining relevancy in the workplace. As a professional trainer, certification sends a clear message to those within the industry that a neutral third party has validated my baseline skill-sets, both as an instructor and hydraulics professional.

Q

What did you learn from the certification process?

As an individual degreed in Workforce Education, the mechanics of the certification process were easy for me to understand and accept. What may not be so apparent is that behind the scenes, there is a cyclic process-improvement model at work designed to continually capture and validate the core of what hydraulic industry professionals deem as the “priority skill-sets” within every level of certification.

Q

How has the certification helped your career?

As a senior training specialist, certifying as an Accredited Instructor keeps me focused on industry priorities and sends a clear message to others about my level of commitment to provide the best training possible.

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Q

Why would you recommend others to become certified?

Q

Who was most influential in your fluid power career?

Q

What advice would you give to someone thinking about starting the IFPS certification process?

Q

Where do you see the fluid power industry heading in the next 10 years?

Certification provides third-party validation for a specific measure of understanding. This can be an important differentiator for some within the fluid power industry. Certification is a personal achievement, and as such, it stays with the individual in the event that they choose to leave an organization for another opportunity. Lastly, certification opens the door for comradery and professional interaction with others in the fluid power industry and can be useful for advice, assistance, and networking.

I think many would agree it is hard to narrow down the list of all positive influencers an individual encounters within their working career. When I look back at my transition from the military to the civilian sector, as a training professional, one name stands out for me…that is Tom Blansett. Tom’s message to me was clear: be responsible, be accountable, and be honorable in all you do as a fluid power professional. I can’t imagine a better set of guiding principles.

Focus on the certification that is most relevant to your professional skill-set. This provides the opportunity to maximize the transfer of information and the benefit of certification. As you continue working as a fluid power professional, consider certifications outside your comfort zone. This creates opportunity for increased understanding across the fluid power industry.

As we move forward, I believe fluid power will continue to see growth in the “intuitive plug-and-play” electro-hydraulic applications. I would expect performance similar to how computer software evolved from the time when installing drivers and configuration settings were required to connect a new external printer, to where we are today, with a process that is as simple as plugging a printer to a USB port with the setup autonomous all by computer operating systems. This leap forward will require the understanding of fluid power in addition to a new type of leadership and engineering philosophy with strong backgrounds in electronics and networking in order to create that “next generation – total solution” concept.


INTERNAT IONAL COVERAGE

Canton Fair China HOLDS ITS 119TH SESSION

The 119th session of Canton Fair in China was held in April 2016 with 185,596 overseas buyers from 210 countries and regions around the world in attendance. This year’s session adopted the development concepts of innovation, coordination, green development, opening up, and sharing, focused on specialization, branding, globalization, information application, and market-oriented development. One of its exhibitors, Fenghua Xinchao Automatization Component Co., Ltd. (XCPC Pneumatic), met with customers from 40 different countries. The China Import and Export Fair, also known as the Canton Fair, is held biannually in Guangzhou every spring and autumn, with a history of 55 years since 1957. www.cantonfair.org

PROTEAN ELECTRIC RECEIVES $70 MILLION IN NEW FUNDING FOR IN-WHEEL DRIVE SYSTEMS Protean Electric, a company specializing in the development and commercialization of in-wheel drive systems in Shanghai, China, received $70 million in new funding from GO Scale Capital, Zhejiang VIE Science & Technology Co. Ltd., and Tianjin THSG Corp. (existing investors Oak Investment Partners and GSR Ventures co-invested in the equity financing round) to ramp up production in China of the PD18 production line for electrified vehicles, as well as new product development and formation of a manufacturing joint venture with VIE, an automotive parts supplier in China providing pneumatic and hydraulic brake systems, power-steering assemblies, and engineering plastic parts. www.proteanelectric.com

www.IFPS.org • September/October 2016 • www.FluidPowerJournal.com

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PRODUCT SPOTLIGHT: FILTRATION, FLUIDS, AND SEALS

LMP Series Filters MP Filtri’s improved LMP series filters are available as line mounted with multiple port configurations, duplex, & manifold mounting covering a wide range of applications including medium pressure boost circuits, lubrication circuits, return line and process filtration. Maximum flow to 800 gpm and maximum pressure to 1160 psi. Visit Us 888-263-0090 • sales@mpfiltriusa.com www.mpfiltriusa.com CIRCLE 448

Got Filter? Crossovers and Interchanges Flow Ezy Filters has been supplying filters for over 70 years and all filters are made in the USA. We offer over 26,000 crossovers and interchanges from Parker, Marvel, Vickers, Schroeder, Pall, Hydac, and many more. We have over $2 Million in inventory to choose from, too. You can access our complete listing from our homepage. Go to www. flowezyfilters.com and take a look at our complete product line. Let Flow Ezy be your filter supplier to help your customer flow easy!

Flow Ezy Filters, Inc. S-80547

Stops Leaking Hydraulic Lines

Phone: 800-237-1165 Fax: 800-252-1730 Email: flowezy@flowezyfilters.com Website: www.flowezyfilters.com CIRCLE 450

Save Time • Save Money • Save Labor • Save Oil • No tools required, one hand installation • No expensive hardware needed • No more rags stuffed into hoses • No more messy plastic caps • The ultimate contamination control tool • Eliminate hydraulic oil spills & clean up • Quick installation & ease of usage • Safe for personnel & environment • Industry acclaimed

FlangeLock™ Contact Mike Pearl at 914.980.8890 or email: mike@flangelock.com • www.flangelock.com CIRCLE 449

BULLDOG® Gasket, Hydraulic Seals and Kits The Bulldog® brand is a premium after-market alternative to the original equipment manufacturer, designed and manufactured for critical, heavy duty applications. In the United States and Latin America, Hercules Sealing Products is the Authorized Master Distributor of Bulldog® Brand Products. Hercules carries the widest selection, in-stock and ready for next day delivery.

Peninsular Cylinder's CAD Configurator Saves Time and Money! PENINSULAR CYLINDER’S CAD CONFIGURATOR is designed to eliminate ordering confusion & complexity in today’s hydraulic & pneumatic cylinder industry. Our CONFIGURATOR allows you to download & quote any NFPA or METRIC standard cylinder - quickly & efficiently. It provides you with our Peninsular part number along with a 2D or 3D cylinder CAD image that can be easily downloaded into your CAD drawings. Our CAD downloads are available in most common 2D & 3D formats. With decades of cylinder engineering & application experience, we build longer lasting cylinders for virtually any cylinder application! Call us for your next cylinder requirement

www.peninsularcylinders.com

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• Engine and transmission gaskets and gasket groups • Head and oil pan gaskets • Seals for steering clutch, crankshaft, air conditioning, water pump, fuel injection, pre-combustion chamber and much more • Cylinder hydraulic seals and kits • All-in-one kits

Hercules® Sealing Products Clearwater, Florida 33765 Phone: 866-885-4407 Fax: 800-759-6391 Place Your Order Online www.HerculesUS.com CIRCLE 452

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SPECIAL ADVERTISING SECTION


SC Hydraulics Newest Addition L6-40 High Volume Pump • • • • • •

Pressures up to 5,000 psi with 125 psi air drive Flows over 4 GPM at no pressure and 3 GPM at 1,000 psi. with 140 scfm air drive All wetted parts stainless steel Compatible with most fluids Air operated - No electricity needed Dimensionally interchangeable with most competitive model pumps

SC Hydraulic Engineering Corporation

Go ahead. Push me.

714-257-4800 • info@schydraulic.com • www.SCHydraulic.com CIRCLE 454

Ordinary heavy duty not heavy enough? Choose Yates Heavy-Duty Mill Cylinders for: • Induction-Hardened, Chrome-Plated Rods • Heavy Wall Tubing • Replaceable Glands & Retainer Rings • High-Load Piston Design

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

Think indestructible and call Yates. www.yatesind.com

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

678.355.2240 CIRCLE 453

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RAF Series Tank Top Return Filter RTF Series Tank Top Return Filter

Unified Code U61 Modular Connectors— Zn-Ni Plated Inserta® Unified Code 61 Modular Elbows and Tee Runs are now available from stock with Zn-Ni plating. Exterior surfaces are plated to ASTM B841 Class 1, Type A, Grade 10 to provide 500 hours of resistance to substrate corrosion in salt fog testing. Inserta® Unified Code 61 Modular Connectors are made with optimized connecting flange footprints. These connectors are smaller, lighter, and more cost effective than standard Modular Connectors. Unified Code 61 Modular Connectors may be used with standard flanges and flange adapters, if adjacent component clearance allows, or with the narrow footprint Adaconn® Unified Code U61 4-Bolt Flange Adapters.

Inserta® Products Blue Bell, PA • www.inserta.com • 215.643.0192

SPECIAL ADVERTISING SECTION

Clean Filtration U.S.A. is proud to offer their RAF and RTF tank top return filter assemblies. With inventory in Corpus Christi these filter assemblies are very competitively priced to meet U.S. market demands. From 3/4" NPT to 3-1/2" SAE code 61 flange porting, these filters offer flow range from 14 GPM to 264 GPM. Synthetic glass fiber filter elements come in 5, 10, and 20 micron ratings for best pressure drop flow conditions. With inventory on the shelf in Corpus Christi, and very competitive pricing, we invite your inquiry.

Clean Filtration U.S.A. 222 S. Navigation Blvd. Corpus Christi, TX 78405 1-888-861-8058 or 713-861-8058. service@cleanfiltrationusa.com www.cleanfiltrationusa.com Visit us at Booth S-81942 March 7-11, 2017 Las Vegas, NV CIRCLE 457

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www.IFPS.org • September/October 2016 • www.FluidPowerJournal.com

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PRODUCT SPOTLIGHT: FILTRATION, FLUIDS, AND SEALS

Visit Our Easy to Use Website Today and Save!

Brassfittingsworld.com - a massive selection of lead free brass fittings, valves and nipples! Responsive customer care and technical support. Quickest delivery and low shipping costs.

Call us at 1.800.569.0810 for all of your lead free brass fittings needs! CIRCLE 458

Corrosion Resistant Window Sights Stainless steel is resistant to corrosion, rust, and staining. It maintains its appearance over long periods and minimizes unwanted bonding between parts. Sight glasses enable viewing inside a reservoir, hydraulic line, or machine compartment. Oil-Rite offers 303 stainless steel window sights with straight or NPT threads. Made in the USA.

Hercules Brand Cylinders Hercules offers a complete line of Tie-Rod and Welded cylinders, designed for a variety of equipment. These cylinders feature iron piston, iron gland with drilled oil passages, honed steel tube, high-tensile, hard-chrome platerod, iron end mounts, female clevises with pins and clips. Cylinders are constructed with an energized loaded u-seal with B lip design and metal canned wiper. Bore sizes start at 1-1/2 to 5 inches and strokes begin at 4-48 inches. To view a complete list of sizes, visit the Hercules® website. Most cylinders are in-stock and ready for next day delivery! Call for special pricing on larger quantities.

Hercules® Sealing Products Clearwater, Florida 33765 Phone: 866-885-4407, Fax: 800-759-6391 Place Your Order Online www.HerculesUS.com

Oil-Rite Corporation (920) 682-6173 • sales@oilrite.com www.oilrite.com CIRCLE 459

CIRCLE 460

“AA” Flange, 1DG Series Double Pumps “A” Flange, 2DG Series Double Pumps “B” Flange, 3DG Series Double Pumps New from Honor Gear Pumps. Now available from Corpus Christi inventory. "B" flange group 3, and "A" flange group 2, and "AA" flange group 1 double pumps are now available from the factory warehouse. Standard group 3 models come with 7/8-13 tooth spline shaft and are available from 52cc on the front pump down to as small as 5cc on the rear. Standard group 2 models come with either the 5/8-9 tooth spline or 5/8" keyed shaft, in displacements from 22cc on the front to 5cc on the rear. Standard group 1 models come with with a 1/2" keyed shaft, in displacements from 9cc on the front to 1cc on the rear. Subject to center section displacements being 5cc, or 7cc, or 9cc, or 11cc, triple pumps are also available in the group 2 size pump frame. Aluminum bodies with cast iron covers are standard heavy duty construction for all Honor single and double gear pumps.

Honor Gear Pumps Corp. Proudly sold through distribution. Please call to be referred. 222 S. Navigation Blvd. • Corpus Christi, TX 78405 Toll free: 800-984-9727 • Local: 713-984-8144 • Fax: 713-461-9631 Email: service@honorpumps.com • Web: www.honorpumps.com CIRCLE 461

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Now Available! Full MTR's and Lot Traceability MAIN Manufacturing Products, Inc. now offers full MTRs and lot traceability on all common flanges. Carbon, stainless, and copper-nickel alloy are available. If not part of our 7000+ in-stock products, MAIN can manufacture and ship quickly- (4-5 days) is common from our US facility.

MAIN Manufacturing Products, Inc. Phone: (800) 521.7918 E-mail: info@mainmfg.com Booth S-81942

www.FluidPowerJournal.com • September/October 2016 • www.IFPS.org

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SPECIAL ADVERTISING SECTION


Cylinder Repair Seal Kits Hercules® carries a full line of replacement seal kits for repair or re-manufacturing of all makes and types of hydraulic cylinders including Caterpillar®, John Deere, Komatsu, Bobcat, Case, Volvo, Hitachi and many more.

Hercules® Sealing Products Clearwater, Florida 33765 Phone: 866-885-4407 Fax: 800-759-6391 Place Your Order Online www.HerculesUS.com

FluiDyne Introduces New V200 Series Vane Pumps Into Product Line FluiDyne is excited to announce the release of a new product: V200 series vane pumps. The vane pumps are rated up to 2000 psi and 1800 rpm. They are offered in dropin replacement on flange mounting (V210), foot mounting (V214) and face mounting (V230) with Buna or Viton seals. The V200 Series has a robust dual shaft bearing design and double lipped shaft seals. Shafts are available in straight keyed long (standard), short, male threaded shaft end and spline. Other shafts are available upon request.

FluiDyne Fluid Power

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From Conception to Completion… CMS Provides the Most Comprehensive Solution! Custom Manifold Systems • Develop Custom Manifold Designs • Manufacture High Quality Manifolds • Deliver OEM Production Quantities • Produce Manifold Sub-Assemblies • Run Systems Testing and Inspection • ISO9001:2008 and AS9100:2009 Certified • Offering a “Complete Solution” to Meet your Power Drive System Needs 59 Industrial Drive • New Britain, PA 18901 215.230.4260 • sales@cmschant.com www.cmschant.com CIRCLE 465

586-296-7200 • sales@fluidynefp.com www.fluidynefp.com CIRCLE 463

D03, D05, D07, D08, D10 Valves & Circuit Stack Modulars

Protection for All Things Hydraulic, Pneumatic and Fluid Power

Power Valve U.S.A. represents, as factory warehouse and sales office, a Taiwan manufacturer of D03, D05, D07, D08, and D10 valves, and modular circuit stack valves. With inventory in the Corpus Christi 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 211GPM (D10) are standard. With inventory on the shelf and very competitive pricing, we invite your inquiry.

MOCAP manufactures a full line of protective closures including recently added sizes and styles of plastic Caps and Plugs for Metric, NPT, BSP, JIC and SAE Threaded Connections, Ports and Fittings. Also, recent additions are a line of Paper Caps and Plugs, as well as Pipe and Flange Protective Products. These are in addition to MOCAP’s already extensive lines of low-cost Caps, Plugs, Grips, Netting, Tubing and Tapes for Product Protection, Finishing and Masking. Nearly all of our items are stocked for immediate shipment and now available in Mini-Pack and Micro-Pack quantities.

Power Valve U.S.A.

www.mocap.com sales@mocap.com 800.633.6775 314.543.4000

Proudly sold through distribution. Please call to be referred. 222 S. Navigation Blvd. Corpus Christi, TX 78405 Contact the company at 713-869-1064 or e-mail to service@powervalveusa.com. View basic specifications at www.powervalveusa.com CIRCLE 466

SPECIAL ADVERTISING SECTION

MOCAP

CIRCLE 467

Visit us at Booth S-81942 March 7-11, 2017 Las Vegas, NV

www.IFPS.org • September/October 2016 • www.FluidPowerJournal.com

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PRODUCT SPOTLIGHT: FILTRATION, FLUIDS, AND SEALS

Adjustable Length Liquid Level Gages Liquid level gages allow viewing of tank contents. Oil-Rite’s proprietary design can accommodate difficult installations with up to 1/2” of variance in the distance between mounting holes. The adjustment is made by hand. No tools or disassembly required. Constructed with durable nylon. Made in the USA.

Oil-Rite Corporation (920) 682-6173 sales@oilrite.com www.oilrite.com CIRCLE 468

Industrial Cylinder Seal Kits

Eaton’s Mobile Fluid Purifier

Hercules® Sealing Products features industrial cylinder seal kits for major brands such as Atlas, Hydro-Line, Miller, Ortman, Parker, Rexroth, Royal, Sheffer, Thompkins-Johnson and Vickers. Rod seal kits can be ordered separately from piston seal kits. Also available are commonly found industrial cylinder cast iron and bronze guide bearings.

Increase the performance and efficiency of your hydraulic and lubrication system with the IFPM 72 Fluid Purifier System • Extends service life of hydraulic and lubricant fluids • Continuous measurement of fluid temperature, water saturation and filter flow-through rates • Removes free, emulsified and dissolved water, free and dissolved gases, and solid contaminants • Visit eaton.com/filtration to view the video

Hercules® Sealing Products Clearwater, Florida 33765 Phone: 866-885-4407, Fax: 800-759-6391 Place Your Order Online www.HerculesUS.com CIRCLE 469

Scan QR code to see how the mobile purifier works

www.eaton.com/filtration CIRCLE 470

CTI-TW Thumbwheel

Solid Models and 3-D Viewer

The CTI-TW Hall Effect Thumbwheel utilizes sealed Non-contacting Hall effect sensors in a polyamide nylon housing. This small and ruggedized thumbwheel is ideally suited for tight clearances in compact control grips and panels. Resistant to vibration, shock, and extremes of temperatures typically found in mobile machine environments. The CTI-TW Hall Effect Thumbwheel offers maintenance free reliable long term use. This thumbwheel is available in three mechanical configurations: Spring Return to Center, Spring Return to Side and Friction Hold. These configurations are available in three electrical output styles: 0.5 to 4.5Vdc, 1.0 to 5.0 Vdc and 0.0-5.0 Vdc signal outputs.

STEP files are now available for ICT Thread-in Check Valves, ICS Slip-in Check Valves, and IBF Ball Valves, from the Inserta® website. 3-D pdf files, as well as an embedded universal 3-D viewer of these products, are also available. Solid models may be found under the ‘Tech Resources’ tab of the website.

Inserta® Products Blue Bell, PA • www.inserta.com • 215.643.0192 CIRCLE 472

Cyber-Tech, Inc. 1.800.621.8754 www.cyber-tech.net CIRCLE 471

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SPECIAL ADVERTISING SECTION


Cylinder Repair Seals Hercules offers over 35,000 inch and metric seals to meet your cylinder repair needs. Product lines include: 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 construction, mining, crane and aerial lift, refuse, agriculture, dump truck, paving, logging and industrial plant applications. Hercules offers the widest selection of in-stock inventory, ready for next day delivery.

Hercules® Sealing Products 1016 North Belcher Road, Clearwater, Florida 33765 Phone: 866-885-4407 Fax: 800-759-6391 Place Your Order Online www.HerculesUS.com CIRCLE 474

Revolutionary AC Servo Motor Driven Control System OEM Linear Slides & Air Cylinders

Imagine your injection molding machine having the best characteristics of hydraulics with the best characteristics of electrics. The Yuken ASR will make this a reality. • High Performance-Extreme low speed molding and continuous pressure holding performance with excellent repeatability. • High Response-Precision molding due to high response injection and a highly efficient piston pump. • Energy Saving-Less than ½ of conventional hydraulic systems • Longer Lifetime-Special servo coupling increases shaft life • Less Wiring-Integrated controller and driver

When built-to-order actuators are beyond the scope of your automation needs, PHD Optimax® provides prefabricated solutions that are economical and efficient, allowing you to integrate reliable components that get the job done. Built on the foundation of quality you’ve come to expect from PHD, these actuators meet machine builders' stringent performance requirements at a more competitive price.

PHD, Inc. (800) 624-8511 • phdinfo@phdinc.com www.phdinc.com/optimax

Yuken – Master Distributor ALA Industries Limited

CIRCLE 473

CIRCLE 475

Tel. (877) 419-8536 • www.yuken-usa.com

YOULI Hydraulic Directional Control Valves

NEW Series of Helical Gear Pumps Marzocchi Pumps has expanded product range on NEW SERIES OF Helical GEAR PUMPS THAT CUTS NOISE LEVELS BY AN AVERAGE OF 15dB(A) OVER CONVENTIONAL MODELS. The ELIKA Quite Pumps range from 7cc-200cc in displacement and go over 4000PSI in pressure depending on flow rates. Marzocchi has a Patent design on the pressure compensated gear profile which allows the pump to reach speeds as low as 200-RPM, with 98% Efficiency. We are planning to introduce also a Group-1 range in 2017.

Marzocchi Pumps gregs@marzocchipumpsusa.com marzocchipumpsusa.com

Direct Acting Electric Solenoids...now available: Youli directional control valves, rated to 4600psi, monoblock or sectional styles, are now available from stock in Corpus Christi, with electric direct acting solenoids on the MB-4 series, rated to 10GPM. Pneumatic operators are also available on all Youli valves, and also kept in stock. 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 Corpus Christi, Texas, and offered at competitive prices, is growing our reputation.

Youli Hydraulic Industrial Co., Ltd. Proudly sold through distribution. Please call to be referred. Contact the company at 1-888-330-8041 or email to service@youli-america.com View basic specifications at www.youli-america.com Visit us at Booth S-81942 March 7-11, 2017 Las Vegas, NV CIRCLE 477

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PRODUCT SPOTLIGHT: FILTRATION, FLUIDS, AND SEALS

Seals on Demand Hercules Sealing Products has expanded the Seals on Demand program to include new styles and materials, and an extended cut-off time. Place your custom seals order by 3:30 p.m. ET and receive your seals the next day, Guaranteed! Visit the “Custom Seals” link on the Hercules website to receive a same day quote, or view a complete list of styles, materials and size ranges. Available styles include: Piston, rod and rotary shaft seals, wipers, back-up and guide rings in over 125 standard profiles. Custom profiles are available within a few days. For questions regarding our Same Day Seals on Demand program, please call 866-885-4407, or visit www.HerculesUS.com.

TORQTITE Adjustable Torque Wrenches Flaretite’s new adjustable open-end torque wrenches allow all tube and hose ends to be precisely tightened to their correct torque requirements. These new wrenches can be used on all fittings requiring a torque specification. Developed to compliment Flaretite’s patented flared seals for 30, 37 and 45 degree flare fittings, these wrenches are used by quality conscious mechanics in all industries. Torque Wrench Benefits: • Five Sizes with ranges from 7 to 500 ft-lbs (10 - 700 Nm). • Fixed wrench ends with hex sizes (jaw opening) from 7/16” thru 3”. Box ends available as specials. • Ratchet end and adjustable ends also available. • Low profile, reversible, spanner design • Precision quality design with +/- 5% accuracy • Shipped with torque rating tables for all common fittings

Hercules® Sealing Products Clearwater, Florida 33765 Phone: 866-885-4407, Fax: 800-759-6391 Online Quotes Now Available www.HerculesUS.com CIRCLE 478

Flaretite, Inc. Fenton, MI, USA • Tel: 810-750-4140 • www.flaretite.com CIRCLE 479

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TIE-ROD TYPE CYLINDERS MILL TYPE CYLINDERS PRESS CYLINDERS METRIC CYLINDERS WELDED TYPE CYLINDERS ALL MOUNTING STYLES

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CALENDAR OF EVENTS

October 3,5,10,12,17,19 IFPS Pneumatic Specialist Fall 2016 Live Distance Learning Contact IFPS: 800-308-6005 ifps.org 3-5 Hydrostatic Closed-Loop Systems for Engineers Cincinnati, OH CFC-Solar, Inc. Tel: 513-874-3225 cfcindustrialtraining.com 3-7 Hydraulic Schematics Maumee, OH Eaton Hydraulics Training Tel: 800-413-8809 hydraulicstraining@ eaton.com 4,6,11,13,18,20 Live Online: Hydraulic Specialist Review First Two Weeks: 6-9 p.m. Third week: 5-9 p.m. CFC-Solar, Inc. Tel: 513-874-3225 cfcindustrialtraining.com 4-7 IFPS Industrial Hydraulic Mechanic Review and Test Virginia Beach, VA (NTT Training) Contact IFPS: 800-308-6005 ascheer@nttinc.com 4-7 Advanced Mobile Hydraulics Elk Grove Village, IL Parker Hannifin Tel: 216-896-2495 mctrain@parker.com

6-8 Introduction to Pneumatics – Concepts and Components Cincinnati, OH CFC-Solar, Inc. Tel: 513-874-3225 cfcindustrialtraining.com 10 Introduction to Mobile Electric – Using a Multi-meter Cincinnati, OH CFC-Solar, Inc. Tel: 513-874-3225 cfcindustrialtraining.com 10-14 Advanced Industrial Hydraulics Maumee, OH Eaton Hydraulics Training Tel: 800-413-8809 hydraulicstraining@ eaton.com 10-14 Principles of Hydraulics Bethlehem, PA Bosch Rexroth Tel: 610-997-6745 training@boschrexroth.com 10-15 Level 1 Industrial Hydraulics – In-depth Fundamentals Cincinnati, OH CFC-Solar, Inc. Tel: 513-874-3225 cfcindustrialtraining.com 10-12 2016 Fluid Power Innovation and Research Conference Minneapolis, MN Contact NFPA: 414-778-3344 nfpa.com

11-13 IFPS Hydraulic Specialist Certification Review and Test Eden Prairie, MN Eaton Hydraulics Training Tel: 800-413-8809 hydraulicstraining@ eaton.com 11-14 IFPS Industrial Hydraulic Mechanic Review and Test Riverside, CA (NTT Training) Contact IFPS: 800-308-6005 ascheer@nttinc.com 11-14 Hydraulic Maintenance Technology Elyria, OH Parker Hannifin Tel: 216-896-2495 mctrain@parker.com 12-14 HYi-303 (formerly PCD) Ontario, Canada Bosch Rexroth Canada Tel: 905-735-0510 boschrexroth.ca/training 13-14 Pneumatic Troubleshooting Using Schematics Cincinnati, OH CFC-Solar, Inc. Tel: 513-874-3225 cfcindustrialtraining.com 17-19 IFPS Hydraulic Specialist Review and Test Cincinnati, OH CFC-Solar, Inc. Tel: 513-874-3225 cfcindustrialtraining.com

A COMPLETE RANGE OF SENSORS:

RELIABILIT Y IN MOBILE HYDRAULIC CONTROLS!

17-21 HYi-201 (formerly MRS) British Columbia, Canada Bosch Rexroth Canada Tel: 905-735-0510 boschrexroth.ca/training 17-21 Pumps and Controls, Open/Closed Loop Bethlehem, PA Bosch Rexroth Tel: 610-997-6745 training@boschrexroth. com 17-21 Mobile Hydraulics Eden Prairie, MN Eaton Hydraulics Training Tel: 800-413-8809 hydraulicstraining@ eaton.com 17-21 Troubleshooting Maumee, OH Eaton Hydraulics Training Tel: 800-413-8809 hydraulicstraining@ eaton.com 18-21 Industrial Hydraulic Technician Certification Review and Test Virginia Beach, VA Contact IFPS: 800-308-6005 ascheer@nttinc.com 18-21 Mobile Hydraulic Technology Milton, Ontario, Canada Parker Hannifin Tel: 216-896-2495 mctrain@parker.com

20 IFPS Webinar: “Machine Safety Overview (Pneumatic Focus) Presented by Jon Jensen, CFPAI SMC Corp. Contact IFPS: 800-308-6005 ifps.org 24-25 Introduction to Mobile Fluid – Power Concepts and Components Cincinnati, OH CFC-Solar, Inc. Tel: 513-874-3225 cfcindustrialtraining.com 24-27 IFPS Electronic Control Specialist Review and Test Cincinnati, OH CFC-Solar, Inc. Tel: 513-874-3225 cfcindustrialtraining.com 24-28 Industrial Hydraulic Principles Bethlehem, PA Applied Motion Technologies, Inc. Tel: 610-333-5689 Lisa.walker@ amthydraulics.com

31 Maintenance – Hydraulic Safety Cincinnati, OH CFC-Solar, Inc. Tel: 513-874-3225 cfcindustrialtraining.com 31-NOV 4 HYm-101 (formerly Introduction to Mobile Hydraulic Technology) Ontario, Canada Bosch Rexroth Canada Tel: 905-735-0510 boschrexroth.ca/training 31-NOV 4 Level 2 Industrial Hydraulics – Advanced Maintenance and Repair Cincinnati, OH CFC-Solar, Inc. Tel: 513-874-3225 cfcindustrialtraining.com 31-NOV 4 Hands-on Hydraulics Bethlehem, PA Applied Motion Technologies, Inc. Tel: 610-333-5689 Lisa.walker@ amthydraulics.com

27-30 IFPS Industrial Hydraulic Technician Certification Review and Test Ontario, CA (NTT Training) Contact IFPS: 800-308-6005 ascheer@nttinc.com

Gefran, a leading global designer and manufacturer of sensors for position, pressure, temperature, and force measurement, now offers a complete range of devices for agricultural machinery.

Gefran sensors use leading edge technology (Hall effect, MEMS, and magnetostrictive) to achieve the demanding requirements of reliability and repeatability in steering, inclination, and acceleration application. LINEAR DISPLACEMENT TRANSDUCERS WIRE POSITION TRANSDUCERS ANGULAR SENSORS INCLINATION SENSORS PRESSURE TRANSDUCERS LOAD CELLS

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CASE STUDY

Contamination Control

SYSTEM DOES THE

DIRTY WORK The mobile CCS4 contamination control system determines the solid contamination particle size distribution, water saturation, and fluid temperature. The CCS4 measurement results provide a basis for analyzing the wear on hydraulic components, observing standards and detecting damage early.

Eaton’s condition-monitoring system helps industrial vacuum truck manufacturer determine the condition of hydraulic oil and sources of contamination to improve product performance. Background

Unified Modular Fittings

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N availabOW le zinc nic with platingkel

Dirty hydraulic fluid is the root cause of up to 80% of all hydraulic system problems. If hydraulic oil is contaminated, there are a number of potentially detrimental effects that can diminish performance or damage system components. Potential ramifications include surface corrosion and accelerated fatigue of metal components. Another effect is distinct changes in the physical characteristics of the oil itself, resulting in hydraulic oil that has a different viscosity or compressibility, which can adversely affect the ability of the oil to transfer power. Since 1986, Vac-Con, Inc. has manufactured more than 7,000 custom-built, truck-mounted machines to serve the public and private environmental markets worldwide. It now employs nearly 300 people at its single location in Green Cove Springs, Fla. For more than 25 years, Vac-Con has been manufacturing industrial vacuum trucks and loaders without noticing any issues related to hydraulic oil contamination. But a clear spike in warranty costs and the desire to continually improve product performance and customer satisfaction sparked a comprehensive analysis of its entire operation. The company enlisted the help of Eaton distributor Hydraulic Supply of Sunrise, Fla. to assist with the evaluation, which included an in-depth look at assembly procedures and the quality of the hydraulic oil being used in its new


trucks. The goal was to minimize any water or other contaminants from entering its trucks’ hydraulic systems.

Challenge “After an exhaustive analysis of our entire process, we discovered some areas where we could improve,” said Tom Armstrong, senior engineer at Vac-Con. “We made many changes in the assembly areas and changed procedures to ensure that the oil coming in from our supplier met our cleanliness standards and the oil going directly into the trucks was free of contamination,” added Bill Barnes, Vac-Con’s lean facilitator and process improvement manager. Once the revamped process was in place, the company began looking for a method to regularly and reliably test the oil to measure the success of the new procedures. It also wanted the capability to keep a record of the readings for warranty purposes. Knowing particle size distribution of any contamination, water saturation, and temperature enables the company to evaluate the precise condition of the system and to determine if procedural changes were working. This information helps to promptly initiate actions and cost-saving measures before any failures can occur.

Solution Hydraulic Supply recommended Eaton’s CCS4 contamination control system and a BSS2 bottle-sampling system for the task. The aim of the systems is to provide a reliable, real-time snapshot used to determine hydraulic fluid condition in the field. Users have access to simultaneous instant readings of particulate contamination and fluid aging with a single measurement using calibrated in-line sensors. The ability to monitor hydraulic fluids in real time makes it possible to immediately diagnose component and seal wear, as well as provide a measurable basis for filter and fluid change intervals. The ease and simplicity of the testing procedure makes it possible to test the condition of new fluids as they are introduced into a system to verify the effectiveness of offline filtration systems, as well as the correct storage and transport of the fluids. The difference between knowing the condition of new fluids and waiting for a time-consuming laboratory analysis could be the difference between an efficient, reliable system and an early failure. “This tool gives us a rapid assessment of our efforts without having to wait four or five days for results to come back from a lab,” said Arm-

strong. “It’s a mobile unit that allows us to hook it directly into the truck to test the oil in a closed atmosphere. It’s so easy to use that anyone could come in and follow the directions, even if they had never seen it before.” While this portable testing system can duplicate much of the analytical capability offered by traditional lab-based services, it does not eliminate the need for periodic laboratory tests. It simply changes the frequency with which they are required and the nature of the tests performed. For example, when particle counts begin to increase, operators will initiate sending samples to the lab to identify contaminants and resolve these issues early on.

Results

to delivery to its customers. The company did not test trucks for hydraulic oil contamination under its past procedures. Since installation, the company has tested more than 650 trucks, and preliminary results show that the suspected issue with water contamination was isolated. “The whole process has required a lot of work, but it has been worth it,” commented both Barnes and Armstrong. “Since we began testing, we have not had to replace a single valve or pump in our assemblies. We also have not had a single failure in the field, and our warranty costs have dropped significantly. This tool allowed us to sustain our improved procedures and ensure that the oil going into our trucks is pure when it leaves our facility. And that ultimately benefits our customers.”

The industrial vacuum trucks represent a significant investment for the company, costing from $150,000 to $400,000 each, so eliminating or managing any hydraulic oil contamination is vital. The customer was so impressed with initial testing of the BSS2 that it constructed a new building where it could use the Eaton equipment to test every vehicle’s hydraulic fluid prior

For more information

Visit www.eaton.com/filtration.

Air Compressors

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

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IFPS UPDATES

2016 Annual Meeting Join the IFPS from September 19-24, 2016 for its 2016 Annual Meeting at the Hotel Phillips in Kansas City, Mo. The Annual Meeting is a great opportunity to network with your fellow professionals in the fluid power and motion control industry. In addition to committee and board meetings, optional activities are planned throughout the week. A technical workshop, “Systems Approach to Saving Power and Boosting Productivity” presented by Dean Houdeshell, CFPAI, Cemen Tech, Inc., will be held on Monday, September 19. Participation in this workshop contributes towards re-accreditation requirements. You may register for the meeting and/or workshop by visiting www.ifps.org or by calling IFPS Headquarters at 800-308-6005.

discounted rate, hotel reservations must be made by August 19, 2016. Reservations can be made online (visit www.ifps.org) or by calling the Hotel Phillips (be sure to mention group name – International Fluid Power Society – to secure the group discount).

Technical Workshop

September 19, 2016 “Systems Approach to Saving Power and Boosting Productivity” 8:00 am–4:00 pm (lunch included) Registration: $150.00 Presented by: Dean Houdeshell, CFPAI, Cemen Tech, Inc. Efficient consumption of energy is one of the key concerns around the world. With increasing use of electronics in mobile hydraulic machines, Hotel Reservations designers are able to develop smarter, more A discount hotel rate of $159.00 + tax /night efficient hydraulic systems. We’ll discuss several has been secured for all IFPS members attending different systems and learn ways to save power and4:57:34 boost productivity in this workshop. the meeting. In order to take advantage1 of 8/5/2016 the clinton_1_third_Ad_Fin3.pdf PM

Schedule of Events Monday, September 19, 2016 8:00 am-4:00 pm “Systems Approach to Saving Power and Boosting Productivity” Tuesday, September 20, 2016 8:00 am-9:00 am Strategic Planning Committee Meeting 9:00 am-11:30 am Education Committee Meeting 11:30 am-12:30 pm Hosted Lunch 12:30 pm-2:30 pm Membership Committee Meeting 2:30 pm-5:30 pm Altec Industries, Inc. Tour 6:00 pm-7:30 pm Welcome Reception 8:00 pm-10:00 pm Night Out Wednesday, September 21, 2016 8:00 am-12:00 pm Certification Committee Meeting 12:30 pm-2:30 pm Harley-Davidson Factory Tour 6:00 pm-10:00 pm Kansas City BBQ Tour Thursday, September 22, 2016

C

8:00 am-11:30 am M

Educational Foundation Meeting 11:30 am-1:00 pm

Y

Lunch (on own)

CM

1:00 pm-3:00 pm

MY

Marketing Committee Meeting 3:00 pm-4:30 pm

CY

Finance Committee Meeting

CMY

6:30 pm-9:00 pm

K

Annual Dinner Friday, September 23, 2016 8:00 am-11:00 am Board of Directors Meeting 11:00 am-12:00 pm Strategic Planning Committee Follow Up 1:00 pm-4:00 pm Job Performance Testing CIRCLE 427

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Web Seminars Did you know that IFPS offers archived web seminars for its members and that you can earn 1 point per web seminar when it is time to recertify? Visit www.ifps.org to register. Upcoming Web Seminars • Machine Safety Overview (Pneumatic Focus) Presenter: Jon Jensen, CFPAI, SMC Corp. of America October 20, 2016 / 12:00 - 1:00 p.m. EST • Proportional Directional Control Valve Systems for Mobile Hydraulics Presenter: Randall Bobbitt, CFPS, Danfoss December 8, 2016 / 12:00 - 1:00 p.m. EST Archived Web Seminars Safety • In the Line of Fire: Cause and Dangers of Fluid Injection Injuries Presenter: Dan Helgerson, CFPAI, CFPSOS, LLC Energy Savings • Pressure Controls: Factors to Predict Setting In Applications Presenter: Ernie Parker, CFPAI, retiredHennepin Technical College • How to Fix an Air Leak So It Stays Fixed Presenter: Jon Jensen, CFPAI, SMC Corp. of America • Energy Efficiency of Hydraulic Components (Advanced Level) Presenter: Jose M. Garcia. Ph.D. CFPHS, Purdue University • Watts It All About? The Use & Misuse of Energy in Fluid Power Systems Presenter: Dan Helgerson, CFPAI, CFPSOS LLC, Perisseuma Energy LLC • Energy Savings in Pneumatic Systems Presenter: Jon Jensen, CFPAI, SMC Corp. of America • Designing and Building a Machine for Energy Conservation Presenter: Jon Jensen, CFPAI, SMC Corp. of America Hydraulics • I0 – Link: High Level Basics & Functionality Presenter: Sam Skelton, CFPAI, Festo Corp. • Cylinder Repairs Presenter: Jeff Kenney, CFPIHM, CFPMHM, CFPMHT, Coastal Hydraulics, Inc. • Contamination Study of a Hydraulic System Using a Variable Volume Reservoir Presenter: Jose Garcia, CFPHS, Purdue University • Proportional Valve Amplifiers - Setup, Tuning, and Troubleshooting Presenter: Ken Dulinski, CFPAI, Macomb Community College • Proper Sizing of Conductors When Using Single Rod Cylinders Presenter: Ernie Parker, CFPAI, retired Hennepin Technical College

• Filter Sizing: Pressure vs. Return Flow Filters Presenter: Bill Hotchkiss, CFPAI, SunSource • Cavitation and Aeration: Causes and Cures Presenter: Pat Maluso, CFPAI, Western Hydrostatics, Inc. • Fluids and Filtration Basics Presenter: Dean Houdeshell, PE, CFPAI, Cemen Tech Inc. • Proportional Valves Presenter: Ken Dulinski, CFPAI, Macomb Community College • Slip-In Cartridge Valves Presenter: Jim Lane, CFPAI, Motion Industries, Inc. Recording available to IFPS Members • Rules of Thumb - Thumbs Down Presenter: Tom Blansett, CFPAI • Accumulators In Hydraulic Systems Presenter: Jim Lane, CFPAI, Motion Industries, Inc. • Pumps, Controls & Where To Set The Relief Presenter: Bill Hotchkiss, CFPAI, SunSource • Hydro-Mechanical vs. Electro-Hydraulic Solutions Presenter: Dr. Khalil, CFPAI, Milwaukee School of Engineering • Load Sensing Valves in Mobile Hydraulic Systems Presenter: Randy Bobbitt, CFPS, Danfoss • Hydraulic Pump Modeling for Application Engineers Presenter: Dr. Medhat Khalil, CFPAI, Milwaukee School of Engineering • What Is The Difference Between PSIA & PSIG? Presenter: Tom Blansett, CFPAI • Controller Area Network (CANBUS) For Electrohydraulic Systems Presenter: Ken Dulinski, CFPAI, Macomb Community College Pneumatics • Industrial Directional Control Valve Common Spools and Actuation Methods Presenter: Bill Hotchkiss, CFPAI, SunSource • Spool Configuration Selection for Pneumatic Valves Presenter: Richard Throop, CFPAI, Neff Engineering Co., Inc. • Vacuum Basic Concepts Presenter: Richard Throop, CFPAI, Neff Engineering Co., Inc. • Pneumatic Filtration Presenter: Bob McGray, CPFAI, SMC Corp. of America Other • Mobile Equipment Reservoir Baffle Innovation Presenter: Robert Post, CFPHS, Bailey Hydraulics

Disclaimer: Although IFPS strives for the highest quality in the resources offered here, unless otherwise noted the IFPS is not responsible for the validity or accuracy of the material presented on the IFPS website. Materials on IFPS website are thought to be accurate, but no warranties, expressed or implied, are made. IFPS disclaims any warranty of merchantability or warranty of fitness for a particular purpose. IFPS will not be held liable for any direct, consequential, or other damages resulting from the negligence of IFPS or its agents. Use of this website constitutes understanding and acceptance of these provisions.

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AVAILABLE IFPS CERTIFICATIONS

IFPS UPDATES

CFPAI Certified Fluid Power Accredited Instructor

IFPS Meeting Dates September 20-23, 2016 2016 Annual Meeting • Kansas City, MO

September 25-29, 2017 2017 Annual Meeting • Location tba

February 20-24, 2017 2017 Spring Meeting • Orlando, FL

February 26 - March 2, 2018 2018 Spring Meeting • Location tba September 24-28 2018 2018 Annual Meeting • Location tba

March 7-11, 2017 IFPE 2017 • Las Vegas, NV Booth SL80130

CFPAJPP Certified Fluid Power Authorized Job Performance Proctor CFPAJPPCC Certified Fluid Power Authorized Job Performance Proctor Connector & Conductor CFPE Certified Fluid Power Engineer CFPS Certified Fluid Power Specialist (Must Obtain CFPHS, CFPPS) CFPHS Certified Fluid Power Hydraulic Specialist CFPPS Certified Fluid Power Pneumatic Specialist CFPECS Certified Fluid Power Electronic Controls Specialist

CERTIFICATION REVIEW TRAINING TEST DATE (WRITTEN & JP)

LOCATION

REVIEW DATE

Fairfield, OH

December 5-8, 2016

FACILITY

CONTACT

CFPMT Certified Fluid Power Master Technician (Must Obtain CFPIHT, CFPMHT, & CFPPT)

register@cfc-solar.com

CFPIHT Certified Fluid Power Industrial HydraulicTechnician

ELECTRONIC CONTROLS SPECIALIST (ECS) December 8, 2016

CFC Industrial Training

HYDRAULIC SPECIALIST (HS) Eden Prairie, MN

March 20 – April 13, 2017

April 17, 2017

Hennepin Tech

eparker@ hennepintech.edu

Denver, CO

June 27-30, 2017

June 30, 2017

NTT Training

ascheer@nttinc.com

Virginia Beach,VA

September 19-22, 2017

September 22, 2017

NTT Training

ascheer@nttinc.com

INDUSTRIAL HYDRAULIC MECHANIC (IHM) Dallas,TX

November 15-17, 2016

November 18, 2016

NTT Training

ascheer@nttinc.com

Denver, CO

July 18-21, 2017

July 21, 2017

NTT Training

ascheer@nttinc.com

Virginia Beach,VA

October 3-6, 2017

October 6, 2017

NTT Training

ascheer@nttinc.com

Virginia Beach,VA

September 13-16, 2016

September 16, 2016

NTT Training

ascheer@nttinc.com

Denver, CO

June 20-23, 2017

June 23, 2017

NTT Training

ascheer@nttinc.com

Virginia Beach,VA

September 12-15, 2017

September 15, 2017

NTT Training

ascheer@nttinc.com

MOBILE HYDRAULIC MECHANIC (MHM)

INDUSTRIAL HYDRAULIC TECHNICIAN (IHT) Fairfield, OH

Call for dates

Call for dates

CFC Industrial Training

Phone: 513-874-3225

Ontario, CA

October 27-29, 2016

October 30, 2016

NTT Training

ascheer@nttinc.com

Irving (Dallas),TX

December 6-8, 2016

December 9, 2016

NTT Training

ascheer@nttinc.com

Denver, CO

July 11-14, 2017

July 14, 2017

NTT Training

ascheer@nttinc.com

Virginia Beach,VA

October 17-20, 2017

October 20, 2017

NTT Training

ascheer@nttinc.com

MOBILE HYDRAULIC TECHNICIAN (MHT)

CFPMHT CertifiedFluidPower Mobile HydraulicTechnician CFPPT Certified Fluid Power PneumaticTechnician CFPMM Certified Fluid Power Master Mechanic (Must Obtain CFPIHM, CFPMHM, & CFPPM) CFPIHM CertifiedFluidPower Industrial HydraulicMechanic CFPMHM Certified Fluid Power Mobile Hydraulic Mechanic CFPPM Certified Fluid Power Pneumatic Mechanic CFPMIH Certified Fluid Power Master of Industrial Hydraulics (Must Obtain CFPIHM, CFPIHT, & CFPCC) CFPMMH CertifiedFluidPower Master of Mobile Hydraulics (Must Obtain CFPMHM, CFPMHT, & CFPCC) CFPMIP Certified Fluid Power Master of Industrial Pneumatics (Must Obtain CFPPM, CFPPT, & CFPCC)

Fairfield, OH

Call for dates

Phone: 513-874-3225

CFC Industrial Training

register@cfc-solar.com

Denver, CO

June 20-23, 2017

June 23, 2017

NTT Training

ascheer@nttinc.com

Virginia Beach,VA

September 12-15, 2017

September 15, 2017

NTT Training

ascheer@nttinc.com

CFPSD Fluid Power System Designer

Phone: 513-874-3225

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

PNEUMATIC TECHNICIAN (PT) Fairfield, OH

Call for dates

Call for dates

CFC Industrial Training

CONNECTOR & CONDUCTOR (CC) Cincinnati, OH

December 13-15, 2016

December 15, 2016

NTT Training

ascheer@nttinc.com

Virginia Beach,VA

March 7-9, 2017

March 9, 2017

NTT Training

ascheer@nttinc.com

Denver, CO

August 22-24, 2017

August 24, 2017

NTT Training

ascheer@nttinc.com

30

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CFPCC Certified Fluid Power Connector & Conductor


NEWLY CERTIFIED PROFESSIONALS Ray Altiery, HS Bosch Rexroth Corporation

Joseph Brandner, HS Vermeer Mfg. Co.

Sidonia Anca, S, HS Stewart & Stevenson Canada, Inc.

Tyler Buck, HS Bosch Rexroth Corporation

Colin Anderson, PM, CC The Boeing Company

Brandon Buffington, MHM Baltimore Gas & Electric Co.

Andrea Ballesio, PM The Boeing Company Garrett Barbari, S, PS NMC CAT Gabriel Bauer, PM The Boeing Company Bradford Belote, S, PS Zemarc Corporation Dave Berard, CC The Boeing Company James Birch, PM The Boeing Company Alexandra Black, MHM Altec Industries, Inc. Matthew Bourassa, HS Norcan Fluid Power Gordon Bradshaw, MM, PM – HCT

Michael Dalessandro, IHM – Bosch Rexroth Corporation

Stephen Hanley, IHM Electro-Hydraulic Machinery Co.

John Davis, PM The Boeing Company

Rocky Herpst, IHM Bonneville Power Administration

Jeffery Deno, MHM Altec Industries, Inc.

Donald Hibbs III, PM. CC The Boeing Company

Phillip Buffone, MHT FEMCO

Douglas Diaz, IHM Electro Hydraulic Machinery Co. Inc.

Robert Cabello, MHM American Electric Power Co.

Mark Dill, Sr., MHM Baltimore Gas & Electric Co.

William Caldwell, HS NTT, Inc.

David Drago, HS Hydradyne LLC

Tate Hoisington, HS Open Loop Energy, Inc.

Matthew Chapman, MHM – Altec Industries, Inc.

Eric Earl, MHM Altec Industries, Inc.

Nicholas Cherpeski, PM The Boeing Company

Kara Frank, MHM Altec Industries, Inc.

Dave Holota, IHM Bosch Rexroth Corporation

Jay Cook, PM The Boeing Company

Juan Gallina, HS

David Hudock, IHM Bosch Rexroth Corporation

David Gregush, IHM Seattle City Light

Ross Jhanson, CC The Boeing Company

Joan Hanley, IHM Electro-Hydraulic Machinery Co.

Kelvis Jimenez, HS CASE Construction

Hugh Cox, CC The Boeing Company Troy Cox, IHM Bonneville Power Administration

Steve Hill, MHM Baltimore Gas & Electric Co. Clair Himes, MHT FEMCO

Hunter Johnson, MHM Altec Industries, Inc.

Trent Kangas, HS Daniel Kumpula, IHM City of Vancouver Kevin Lang, MHM Baltimore Gas & Electric Co. Matthew Lauer, IHM Bosch Rexroth Corporation Daniel Libby, PS The Boeing Company Colin Loudermilk, S, PS Aerospace Testing Alliance Kevin Love, IHM Bosch Rexroth Corporation

Joseph Maynard, MHM Altec Industries, Inc.

Josh Reed, MHM Altec Industries, Inc.

John Mecham, MHM Altec Industries, Inc.

Jay Smith, HS Hydradyne, LLC

Christopher Mills, HS Oshkosh Corporation

Gabriel Stauffer, HS Terex Utilities, Inc.

Rylan Monroe, HS Motion Industries, Inc.

David Stinson, IHT Hydradyne LLC

Ken Morris, PS

Ryan Tietz, E SunSource

Roel Nino, MHT – FEMCO David Noseworthy, HS Parker Hannifin Marty O’Connell, MHM Altec Industries, Inc. Hiteshkumar Patel, HS

Nemesio Lusuegro, CC The Boeing Company

Henry Pontiveros, MHM Altec Industries, Inc.

Travis Mamone, IHM Electro Hydraulic Machinery Co. Inc.

Jordan Porter, HS GS Global Resources

Dusty Marshall, MHM Richard Mask, MHT FEMCO

Josh Rand, MHM Baltimore Gas & Electric Co. Michael Rau, ECS Nebraska Machine Company

Westly Torbet, MHM Altec Industries, Inc. Grant Towns, CC The Boeing Company Clement Travert, IHM Electro Hydraulic Machinery Co. Inc. Casey Weismiller, IHT Bosch Rexroth Corporation Zachary Wickline, IHT Hydradyne LLC Sean Wright, MHT FEMCO

Sunfab.com CIRCLE 429

CIRCLE 430

www.IFPS.org • September/October 2016 • www.FluidPowerJournal.com

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INDIVIDUALS WISHING TO TAKE ANY IFPS WRITTEN CERTIFICATION TESTS

IFPS UPDATES

IFPS Certification Testing Locations ALABAMA Auburn, AL Birmingham, AL Jacksonville, AL Mobile, AL Montgomery, AL Normal, AL Tuscaloosa, AL ALASKA Anchorage, AK Fairbanks, AK ARIZONA Flagstaff, AZ Glendale, AZ Mesa, AZ Phoenix, AZ Prescott, AZ Safford, AZ Scottsdale, AZ Sierra Vista, AZ Tempe, AZ Thatcher, AZ Tucson, AZ Yuma, AZ ARKANSAS Bentonville, AR Hot Springs, AR Little Rock, AR CALIFORNIA Arcata, CA Aptos, CA Bakersfield, CA Encinitas, CA Fresno, CA Irvine, CA Marysville, CA Riverside, CA Sacramento, CA Salinas, CA San Diego, CA San Jose, CA San Luis Obispo, CA Santa Ana, CA Santa Maria, CA Santa Rosa, CA Yucaipa, CA COLORADO Aurora, CO Boulder, CO Centennial, CO Colorado Springs, CO Denver, CO Durango, CO Ft. Collins, CO Greeley, CO Lakewood, CO Littleton, CO Pueblo, CO DELAWARE Dover, DE Georgetown, DE FLORIDA Avon Park, FL Boca Raton, FL Cocoa, FL Davie, FL

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Daytona Beach, FL Fort Pierce, FL Ft. Myers, FL Gainesville, FL Miami Gardens, FL New Port Richey, FL Orlando, FL Panama City, FL Pembroke Pines, FL Pensacola, FL Plant City, FL Sanford, FL St. Petersburg, FL Tampa, FL Winter Haven, FL GEORGIA Albany, GA Athens, GA Atlanta, GA Carrollton, GA Dahlonega, GA Dublin, GA Dunwoody, GA Lawrenceville, GA Morrow, GA Oakwood, GA Statesboro, GA Tifton, GA Valdosta, GA HAWAII Laie, HI IDAHO Boise, ID Coeur d ‘Alene, ID Idaho Falls, ID Lewiston, ID Moscow, ID Nampa, ID Rexburg, ID Twin Falls, ID ILLINOIS Carbondale, IL Carterville, IL Champaign, IL Decatur, IL DeKalb, IL Edwardsville, IL Glen Ellyn, IL Joliet, IL Malta, IL Peoria, IL Springfield, IL INDIANA Bloomington, IN Evansville, IN Fort Wayne, IN Gary, IN Indianapolis, IN Kokomo, IN Lafayette, IN Lawrenceburg, IN Madison, IN Muncie, IN New Albany, IN Sellersburg, IN South Bend, IN Terre Haute, IN

IOWA Ames, IA Cedar Rapids, IA Iowa City, IA Ottumwa, IA Sioux City, IA Waterloo, IA KANSAS Lawrence, KS Manhattan, KS Wichita, KS KENTUCKY Bowling Green, KY Covington, KY Highland Heights, KY Louisville, KY Morehead, KY LOUISIANA Bossier City, LA Monroe, LA Natchitoches, LA New Orleans, LA Thibodaux, LA MARYLAND Arnold, MD Bel Air, MD Frederick, MD Hagerstown, MD La Plata, MD Westminster, MD Wye Mills, MD MASSACHUSETTS Boston, MA Bridgewater, MA Danvers, MA Haverhill, MA Holyoke, MA MICHIGAN Ann Arbor, MI Big Rapids, MI Dearborn, MI Dowagiac, MI East Lansing, MI Flint, MI Grand Rapids, MI Kalamazoo, MI Lansing, MI Livonia, MI Mason, MI Mount Pleasant, MI Sault Ste. Marie, MI Troy, MI University Center, MI Warren, MI MINNESOTA Brooklyn Park, MN Eden Prairie, MN Granit Falls, MN Mankato, MN Morris, MN MISSISSIPPI Goodman, MS Mississippi State, MS Raymond, MS University, MS

MISSOURI Cape Girardeau, MO Cottleville, MO Joplin, MO Kansas City, MO Kirksville, MO Park Hills, MO Poplar Bluff, MO Rolla, MO Sedalia, MO St. Joseph, MO St. Louis, MO Warrensburg, MO MONTANA Bozeman, MT Missoula, MT NEBRASKA Bellevue, NE Lincoln, NE North Platte, NE Omaha, NE NEVADA Henderson, NV North Las Vegas, NV Winnemucca, NV NEW JERSEY Branchburg, NJ Lincroft, NJ Sewell, NJ Toms River, NJ West Windsor, NJ NEW MEXICO Albuquerque, NM Clovis, NM Farmington, NM Portales, NM Santa Fe, NM NEW YORK Brooklyn, NY Buffalo, NY Garden City, NY Middletown, NY New York, NY Syracuse, NY NORTH CAROLINA Apex, NC Asheville, NC Boone, NC Charlotte, NC Durham, NC Fayetteville, NC Greensboro, NC Greenville, NC Jamestown, NC Misenheimer, NC Pembroke, NC Raleigh, NC Wilmington, NC NORTH DAKOTA Bismarck, ND Fargo, ND OHIO Akron, OH Cincinnati, OH

www.FluidPowerJournal.com • September/October 2016 • www.IFPS.org

Columbus, OH Fairfield, OH Findlay, OH Kirtland, OH Lima, OH Maumee, OH Newark, OH Orrville, OH Rio Grande, OH Toledo, OH Youngstown, OH OKLAHOMA Altus, OK Bethany, OK Edmond, OK Norman, OK Oklahoma City, OK Stillwater, OK Tonkawa, OK Tulsa, OK OREGON Bend, OR Coos Bay, OR Eugene, OR Gresham, OR Medford, OR Oregon City, OR Portland, OR White City, OR PENNSYLVANIA Bethlehem, PA Bloomsburg, PA Blue Bell, PA Gettysburg, PA Harrisburg, PA Lancaster, PA Newtown, PA Philadelphia, PA Pittsburgh, PA York, PA SOUTH CAROLINA Beaufort, SC Charleston, SC Columbia, SC Conway, SC Greenwood, SC Orangeburg, SC Rock Hill, SC Spartanburg, SC TENNESSE Blountville, TN Clarksville, TN Collegedale, TN Gallatin, TN Johnson City, TN Memphis, TN Morristown, TN Murfreesboro, TN Nashville, TN TEXAS Abilene, TX Arlington, TX Austin, TX Beaumont, TX Brownsville, TX Commerce, TX Corpus Christi, TX Dallas, TX

are able to select from 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 a 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 all locations: SEPTEMBER 2016 Tuesday, 9/6 • Thursday, 9/22 OCTOBER 2016 Tuesday, 10/4 • Thursday, 10/20 NOVEMBER 2016 Tuesday, 11/1 • Thursday, 11/17 DECEMBER 2016 Tuesday, 12/6 • Thursday, 12/22 JANUARY 2017 Tuesday, 1/3 • Thursday, 1/19

Denison, TX El Paso, TX Houston, TX Huntsville, TX Laredo, TX Lubbock, TX Lufkin, TX Mesquite, TX Weatherford, TX Wichita Falls, TX UTAH Cedar City, UT Kaysville, UT Logan, UT Ogden, UT Orem, UT Salt Lake City, UT VIRGINIA Daleville, VA Lynchburg, VA Norfolk, VA Roanoke, VA Virginia Beach, VA WASHINGTON Bellingham, WA Bremerton, WA Ellensburg, WA Olympia, WA Seattle, WA Shoreline, WA Spokane, WA

WISCONSIN Fond du Lac, WI La Crosse, WI Milwaukee, WI WYOMING Casper, WY Laramie, WY Torrington, WY ASIA Kindom of Bahrain AUSTRALIA Rockingham, WA CANADA Calgary, AB Edmonton, AB Fort McMurray, AB Lethbridge, AB Lloydminster, AB Olds, AB Red Deer, AB Abbotsford, BC Burnaby, BC Castlegar, BC Delta, BC Kamloops, BC Nanaimo, BC Richmond, BC Surrey, BC Vancouver, BC Victoria, BC

Prince George, BS Brandon, MB Winnipeg, MB Moncton, NB St. John’s, NL St. John’s, NL Halifax, NS Brockville, ON Hamilton, ON Mississauga, ON Niagara-on-theLake,, ON North Bay, ON North York, ON Ottawa, ON Toronto, ON Welland, ON Windsor, ON Côte Saint-Luc, QB Moose Jaw, SK Prince Albert, SK Saskatchewan, SK Whitehorse, YT ENGLAND London NEW ZEALAND Taradale


How to

HANDLE COMPLEX LUBRICATION ISSUES COOPERATION BETWEEN LUBRICANT AND EQUIPMENT MANUFACTURERS SOLVES PNEUMATIC APPLICATION PROBLEMS By Helmut Seubert, Klüber Lubrication München SE & Co. KG Selecting the proper specialty lubricant There are less trivial types of leakage, for pneumatic components, drives, and though, which have to be remedied with control systems may involve complex facconsiderable outlay in terms of time and tors that require extensive tribological costs. Compressed air, for instance, is expertise to understand. That’s because expensive to generate, and therefore, fixpneumatic equipment incorporates a variing leaks is extremely important. There’s a rule-of-thumb saying that it ety of different elements—such as cylinders, motors, or valves—which are costs a nickel for each cubic meter of comprised of different materials that make compressed air generated. Each addithe tribological system highly complex. tional 14.5 psi of compressed air can be A decisive factor for ensuring maxiexpected to increase energy costs by mum service life and proper equipment approximately 10%. This means costs can function is selecting the right pre-start rise enormously, especially when leakages lubrication for all components that go undetected in connecting lines, check move relative to one another, e.g. pisand control valves, quick-fitting pipes, Complex pneumatic components that incorporate a ton rod, cylinder wall, valve slide, and maintenance units, or the terminal equipvariety of different elements, such as cylinders, motors, or valves, which are made of different materials, can be very sealing elements. Furthermore, the ment, such as pneumatic units. demanding in terms of lubrication. lubricants used for reducing friction Besides professional maintenance, and wear must also be tuned to the high-quality design elements—such as ambient temperature, sliding speed, and normal forces, just to name materials, sealing elements, and lubricants—are indispensable to a few factors. ensure economical operation and to extend or eliminate the need for As operating pressures, temperatures, sliding speeds, and stroke component replacement. Consequently, when looking at cost, what matters is not so much the frequencies continuously rise, design engineers and tribologists must carefully understand the friction factors where shafts or rods are taken cost of air compression as such, but rather how much energy is needed to make the compressed air available at the point of use. On average, through housing walls. At the microscopic level, the tribological system that encompasses approximately 33% of compressed air is generated only to vanish through the various gaps, spaces, and friction points involves such factors as a large number of small leaks that combine into a huge loss. ƒƒ intermolecular forces, A simple calculation reveals the expected losses—and the potential ƒƒ thermal transmission and conduction, for improvement. For example, a medium-sized company operates a ƒƒ friction and wear, and 100-kW compressor station with a total runtime of all compressors of ƒƒ chemical and electro-chemical corrosion. about 6,000 hours a year. At a rate of approximately $0.082 per kWh, the At the mechanical level, the tribological analysis must account for annual energy cost is about $48,700. If typical leakages can be prevented, ƒƒ cylinder and rod materials, however, the operator will need 30% less of compressed air, saving ƒƒ different seal materials and sealing edge geometries, roughly $15,000 on energy alone. ƒƒ contact surface pressure and surface micro-geometry, ƒƒ acting pressures, and How Collaboration Identifies Savings ƒƒ mounting position and situation. To prevent leakages from being caused by brittle seals, it is essential Additionally, environmental factors act on the components and the that the seal and the lubricant be compatible. In a recent case, both friction points, e.g. low and/or high temperatures or aggressive media hydrologic and lubrication manufacturers cooperated in using mechain liquid, gaseous, or abrasive form, such as sand, etc. These complex no-dynamical test rigs for tests that closely resembled application and factors are best handled when design and tribology engineers collaborate component realities. By combining knowledge, both parties identified early in the development process to identify the benefits obtainable opportunities for improvement. With the development of seal-and-lufrom proper lubrication selection. bricant combinations for the various tasks encountered in pneumatic systems, operators benefitted from improved pneumatic drives, valves, Preventing Leakage Means Less Energy Consumption and seals. As a result, the machinery was able to operate reliably for long Preventing leakage is key to developing successful pneumatic compo- periods while cutting energy costs considerably—a significant competnents. While a component is in operation, some leaks may go unnoticed, itive advantage resulting from early cooperation that identified the for example when water leaking from a pump evaporates on the spot. relevant tribological and operational factors. For more information: Helmut Seubert is manager, marketing and application engineering, for Klüber Lubrication München SE & Co. KG. He can be reached at helmut.seubert@klueber.com. www.IFPS.org • September/October 2016 • www.FluidPowerJournal.com

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CASE STUDY

Diagnostic

TEST EQUIPMENT

A

MC Jets has over 20 years of experience servicing companies using highpressure water- jet cutting technologies worldwide. A potential and widespread issue in its field of operations is a reduction in hydraulic system pressure, which often leads to performance decay of the water pressure intensifier. AMC Jets went to WEBTEC, a hydraulic measurement and control company, to find a portable monitoring and data capture solution. While the engineers at WEBTEC had never investigated pressure sensing of this magnitude before (72,500 psi), they could see no reason why it couldn’t be incorporated into their data-logging equipment.

Predictive Maintenance Simply put, prevention is better than cure. The concept of predictive maintenance means testing a system that is working in order to predict when it may start to fail, thus enabling maintenance and repair before any catastrophic failure. It allows planned sourcing of expensive parts before they are needed and before a significant reduction in downtime occurs, since parts are usually only available on standby as they are required. It also means that panic jobs are minimized, and so the quality of any maintenance and repair is never compromised. It can save time and money, and the associated lack of unplanned downtime is of huge value.

The AMC Jets Project – High-Pressure Hydraulics Hydraulic pressure measurement alone is insufficient; the behavior of the hydraulic system generating the pressure is also important in

34

www.FluidPowerJournal.com • September/October 2016 • www.IFPS.org

determining the likelihood of failure. Therefore, the engineers at AMC Jets wanted to measure flows, pressures, and temperatures on the power supply hydraulic system and simultaneously measure the intensified water system pressure. They also recognize that contamination is the source of 80% of hydraulic failures, so they also needed to constantly access the condition of the hydraulic oil. Since they were already using a MP Filtri in-line condition monitor, AMC engineers specified this unit as a core requirement, as well as a very high water pressure sensor, which they sourced and supplied themselves. This was an ideal opportunity for WEBTEC to engineer a solution for the client that would ultimately be useful for other clients in other areas of operations. AMC Jets wanted a portable data logger that would be easy to install and use, and discussed several alternatives of flow and pressure sensors, combined with a WEBTEC hydraulic data logger, the HPM6000 series.

The Solution – Bespoke and Portable Within their quotation, WEBTEC clients are provided with embedded hyperlinks to technical datasheets, providing all the information they need to discuss how best to customize their kit precisely, rather than having extraneous and unused cables and sensors. The final engineered solution for the AMC Jets system consisted of a


enabling collaborative test process adjustments along the way. Initial feedback from the client has been positive. AMC Jets believes the data analysis service will be a chargeable service for its own customers, partially refundable on acceptance of service recommendations. The HPM6000 hand-held portable data logger unit comes with HPMcomm™ software, which enables test data to be downloaded and saved, archived to a computer. This benchmark or reference can be repeated months or years later and analyzed by overlaying the old and new data, comparing performance of the same serial number machine over time and gradually identifying its performance decay. A customer’s failing components can be pointed out visually and graphically. The principle behind this system is applicable to different types of hydraulic equipment in the industry, not just water-jet cutting machines. Maintenance only when needed and servicing only components that need to be serviced is as important as reducing unplanned downtime for maintenance. The business advantages can be huge.

Custom Industrial Control Handles, Pendants, Joysticks and Switches

Manufactured To Your Specific Requirements

8901-D Flex-Core

● ● ● ● ● ● ● ●

13 Grip Styles 10 Pendant Styles 4 Joystick Styles Large Switch Variety Control Boxes Wireless Controls CANbus Options USB Interfaces Manufactured To Your Specific Requirements

● ● ● ● ●

Fast Deliveries One-Off Prototypes OEM Discounts US Craftsmanship Demos and Show Display Available Hall Effect Controls

WWW.CYBER-TECH.NET

portable data logger, four flow meters with on-board temperature, four pressure transducers, a particle counter, and all relevant connectors and cables. An important part of the brief for this client was portability. Due to the size and bulk of the system, it is not practical for it to be contained within one carry case, and therefore it was split into two separate cases, the idea being to have a wet and dry case as necessary. They included wheels for easier portability and commuting. Since delivery, the client has decided to add a third to contain all of the flow meters permanently mounted on a single panel, ready to connect on site. The case was also configured with space for a 7-gpm stainless steel, positive-displacement flow meter for monitoring the water hydraulics at a later date. The system itself took around six weeks to implement following some upfront feasibility engineering. The client also required the inclusion of an on-site training session as part of the project and used the projected test regime as an integral part of that training. The data collected was examined to ensure it met with AMC Jets’ objectives,

JS-H100

Pro-H50-TW

Joystick w/Ball Knob

ThumbWheels

For more information, visit www.webtec.com/us.

Standard Output 0.50v- 2.5v- 4.5v

1.800.621.8754 www.IFPS.org • September/October 2016 • www.FluidPowerJournal.com

35

CIRCLE 431

MADE IN THE USA SINCE

1982


FPEF UPDATES

Great Things Come From Outstanding Support! What a few of our past scholarship winners are up to... Caleb Blankemeyer attended Northwest State Community College. He is employed as a CNC machinist at Drainage Products, Inc. in Haviland, Ohio and is also involved in the hydraulics and pneumatics work when fabricating a machine for production. He says, “Applying for the scholarship can open doors for employment. It can also grow your own interest in hydraulics and pneumatics.” Nathan Brace attended Iowa State University. He is employed with John Deere in Dubuque, Iowa. He says, “The Fluid Power Education Foundation Scholarship I received was a huge blessing that really helped with college expenses.  It helped me on my journey through college and increased my interest in the fluid power industry in which I work today.” Andrew Bachman attended Purdue University College of Technology. He was recently hired as an engineering technician at Telamon Industrial Solutions, Carmel, Ind. He says, “As an adult student starting my second career, this scholarship greatly blessed my family and me. It gave me the ability to spend more time with my family instead of working the many extra hours required to pay for school. I cannot thank the donors enough for this gift and hope that, in the future, I will be able to pay it forward to the next class of students. Thank you.”

FPEF FUNDRAISING INITIATIVE THAT GIVES MONEY FPEF raised over $2,500 (more than enough for a full scholarship) with its 2016 Calendar Lottery. One fluid power student will receive a scholarship in April. One weekly lottery winner won $50, and one monthly lottery winner won $100. It’s not too late to get in on the action! You can buy your calendar anytime this year; the sooner you do, the better chance you’ll have of winning. Visit www.fpef.org.

AUGUST 2016 WINNERS $100 – Ed Rybarczyk – Castle Rock, CO $50 – Markie Blansett – Groton, CT $50 – Marti Wendel – Salem, OH $50 – Paul Miller – St. Joseph, MO $50 – Chuck Eackin – Crofton, MD Previous winners can be seen at www.fpef.org.

OE

Now Available SC Hydraulic Engineering introduces its new portable test cart. This compact mobile design offers many popular features found on our standard power units.

SC Hydraulic’s Newest Addition 90 Series Portable Test Cart • Mobile self contained power unit • Air drive controls, pressure • Air operated - No electricity gauges and valves included needed • Used in: • Pressures up to 65,000-psi with Hydrostatic testing 100-psi air drive Burst testing • Available with a 5 or 10 gallon Water-jet blasting stainless steel reservoir Hydraulic press operation • Compatible with most fluids Hydraulic cylinder & valve • Available with all 10-series pumps actuation

*Contact factory for gauges over 60,000 psi SC Hydraulic Engineering Corporation 1130 Columbia Street • Brea, California 92821 • USA Phone (714) 257-4800 • Fax (714) 257-4810 Email info@schydraulic.com www.SCHydraulic.com CIRCLE 432

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www.FluidPowerJournal.com • September/October 2016 • www.IFPS.org

M UP TA T N RT O 3 K TO IN F S 50 P F S E G I NO TO RIE PM LTE W CK S ... RS

HYDRAULIC FILTERS •QUALITY •PRICE •NOW Spin On Heads & Elements Tank Top Filters Sump Strainers High Pressure Filters

CLEAN FILTRATION USA Corpus Christi, Texas 888-861-8058 toll free 713-861-8058 local 713-461-9631 fax service@cleanfiltrationusa.com www.cleanfiltrationusa.com CIRCLE 433

Visit us at Booth S-81942 March 7-11, 2017 Las Vegas, NV


Miniature Pneumatic Products Catalog CLIPPARD INSTRUMENT LABORATORY, INC. • CIRCLE 480

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!

FALL

LITERATURE

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

REVIEW

Industrial Control Solutions

Quality Pumps, Motors, Valves, and Filters

CYBER-TECH, INC. • CIRCLE 481

FLUIDYNE FLUID POWER • CIRCLE 482

Cyber-Tech, Inc. designs and manufactures custom industrial grade control handles, control pendants, mechanical and proportional joysticks with a consistent reputation for being rugged and reliable, while delivering a level of customer service that is superior in the industry. Visit our website and give us a call so we can assist you in your control needs. Cyber-Tech, Inc. www.cyber-tech.net 1.800.621.8754

Your choice for interchange hydraulic pumps, motors, valves and filters.

S-Series High Torque, Low Speed Motor

D05 Stack Valve

PVH Piston Pump

A10V Piston Pump

T6 Drive Train Vane Pump

V10 Vane Pump

www.fluidynefp.com

FluiDyne Fluid Power provides high quality, fully tested, interchangeable hydraulic pumps, motors and valves to distributors and OEMS all around the world. Our customer service team provides what you want, when you need it. Most of our units ship same day or next and have 18 month warranty. Give our customer service team a call to assist you with your hydraulic needs! FluiDyne Fluid Power 586-296-7200 sales@fluidynefp.com www.fluidynefp.com

Mobile Product Overview

HM589 Power Take-Off Series

HAWE HYDRAULIK • CIRCLE 483

HEAVY MOTIONS • CIRCLE 484

This product overview provides you with a summary of the general capabilities and technical information for a variety of HAWE Hydraulik’s components for mobile applications. It is supplemented with additional product-specific pamphlets containing details technical specifications and information on how to order these products. Additional documents are available upon request from your local HAWE office of HAWE.com. HAWE Hydraulik 9009 K Perimeter Woods Dr. Charlotte, NC 28216 704-509-1599 www.HAWE.com

SPECIAL ADVERTISING SECTION

Heavy Motions’ new HM589 power take-off series is designed to work with the most popular medium and heavy duty transmissions. Our HM589 series replaces the 489 series 8-bolt mount PTOs with standard and deep mount, direct and remote pump mount in a wide range of gear ratios. They are 100 % interchangeable, part by part. We also offer spare parts: housings, gears, shafts, shifters, valves, repair kits and more. 2134 S Green Privado

Ontario, CA 91761 www.heavymotions.com

www.IFPS.org • September/October 2016 • www.FluidPowerJournal.com

37


Compressed Air Filtration

Hydraulic Flanges and Components

LA-MAN CORPORATION • CIRCLE 485

MAIN MANUFACTURING PRODUCTS • CIRCLE 486

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

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

Genuine Metaris Gear Pumps Technical Catalog

MRSX Return/Suction Filter Series

METARIS • CIRCLE 487

MP FILTRI USA, INC • CIRCLE 488

This catalog covers all the technical specs, performance data, model code breakdowns, component options and dimensions for Genuine Metaris gear pumps. Available in both bearing and bushing style with multiple gear sizes, mounting flange options, shaft configurations and porting options. These units are perfect alternatives for Commercial®/Parker® and Muncie® gear products. View or download this catalog by visiting our website at www.metaris.com. Metaris – A Hydraulex Global Company Toll Free: 888.477.2737 Tel: 416.638.6000 Email: sales@metaris.com www.metaris.com

MP Filtri USA, Inc. 2055 Quaker Pointe Drive Quakertown, PA 18951 Toll Free: 888-263-0090 Fax: 215-529-1902 email: sales@mpfiltriusa.com www.mpfiltriusa.com

304 & 316 Stainless Steel Liquid Level Gages

PHD, Inc. Releases New Main Catalog

OIL-RITE CORPORATION • CIRCLE 489

PHD, INC. • CIRCLE 490

Corrosive resistant properties make stainless steel gages suitable to a variety of applications. Oil-Rite offers 304 and 316 stainless steel liquid level gages in sizes from 3" to 60". A red line on a white background enhances liquid level visibility. Available with adapters and thermometer. Visit Oil-Rite’s online product catalog for new cut sheets and detailed information. Oil-Rite Corporation PO Box 1207 Manitwoc WI 54221-1207 Phone: (920) 682-6173 Email: sales@oilrite.com www.oilrite.com

38

MP Filtri offers a comprehensive range of hydraulic filters and accessories for the fluid power industry. Our new MRSX filter series focuses on applications for mobile machinery. The MRSX provides combination filtration on return and suction for closed circuit hydraulic transmission, and includes an exclusive hex design cap and element.

www.FluidPowerJournal.com • September/October 2016 • www.IFPS.org

Features: • PHD’s complete comprehensive standard product line • 21 new products • The Optimax® line of global drop-in actuators • The PHD Plus® line of electromechanical actuators • Updated cutaway views, including improved graphics • An updated shipping schedule • An updated guide to each product section • Detailed overviews of PHD’s e-tools (myPHD), Unlimited® Unique Solutions, Blow Molding Solutions (PPC Group), Yamaha Robotics, and PHD’s Rebuild Program phdinc.com | 1-800-624-8511

SPECIAL ADVERTISING SECTION


Product Specifications ROTOR CLIP COMPANY, INC. • CIRCLE 491

Rotor Clip's Product Specification catalog lists full engineering specifications for tapered section retaining rings, constant section rings, spiral rings, wave springs and hose clamps in inch and metric configurations. Also features installation tools for rings and hose clamps. Includes a section on load capacity and other retaining ring formulas, as well as other technical information on Rotor Clip products. Rotor Clip Company, Inc. sales@rotorclip.com www.rotorclip.com

Hydraulic Live Swivels Catalog SUPER SWIVELS • CIRCLE 492

Super Swivels Phone: (763) 784-5531, Fax: (763) 784-7423, Website: www.superswivels.com

.D. O

CIRCLE 434

Stringent Testing, °73

Inline and 90° hydraulic live swivels. Available in sizes from 1/8" to 2-1/2", rated to 10,000 PSI, heat treated, superior quality alloy steel, chrome or stainless steel ball bearings, withstands heavy side loads, burnished (micro smooth) barrel bores, Viton®, Aflas®, or Teflon® encapsulated seals, zinc or nickel plated, available in 304 and 440 stainless steel, full flow - low pressure drop, rebuilding kits available.

Zero Failures. The only flare solution for

Your Cylinder Source

Yates Industries, Inc. 23050 Industrial Dr. E. St. Clair Shores, MI 48080 Ph: 586.778.7680 Fax: 586.778.6565

Yates Georgia 7750 The Bluffs Austell, GA 30168 Ph: 678.355.2240 Fax: 678.355.2241

Yates Alabama 55 Refreshment Place Decatur, AL 35601 Ph: 256.351.8081 Fax: 256.351.8571

° 37

fittings

Before Flaretite

° 37

All Designs, All Sizes, One Result. Yates Cylinders – an ISO-9001:2008 company with facilities in Michigan, Alabama and Georgia – 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. www.yatesind.com

“Leak-Free”

. O.D

. O.D

YATES INDUSTRIES, INC. • CIRCLE 493

Visit our website for

810-750-4140

After Flaretite

FREE

samples!

www.flaretite.com CIRCLE 435

SPECIAL ADVERTISING SECTION

www.IFPS.org • September/October 2016 • www.FluidPowerJournal.com

39


FLOW MEANS

“GO”

...Well, not exactly. By Dan Helgerson, CFPAI/AJPP, CFPS, CFPECS, CFPSD, CFPMT, CFPCC

F

luid power has become a vital component in our ability to perform work: it harvests our crops, takes our waste to the landfill, moves the landing gear, entertains and protects us, and all with a power density and flexibility that is unmatched in any other fluid power transfer system. However, when it comes to efficiency, fluid power systems are not very high on the list. A recent study has shown an average efficiency in fluid power systems to be less than 30% with a cost of billions of dollars in wasted energy. A great deal of work has been done and continues to be done in developing more efficient components: cylinders with lower breakaway, pumps and motors with greater volumetric and mechanical efficiency, compressors driven with variable speeds, and digital variable-displacement pumps. These are all beneficial, but they often come at a substantial cost, which must be weighed against the potential energy savings. A pump that has a high volumetric and mechanical efficiency in a circuit where it is dumping across a relief valve is operating at 100% inefficiency. Even a load-sensing or digital pump is 100% inefficient at minimum displacement. An inefficient circuit with efficient components is still an inefficient system. This article series will ask us to think differently about our fluid power systems.We will look at energy in a different way and discover ways to transform fluid power energy to make our systems more efficient and then be able to make better use of the new and improved components available to us.

We are about to enter a new era in the use of fluid power. To be successful in understanding the changes that are coming, we will need to re-think some of our most cherished notions about power transfer by fluids. For some of us, this will be very uncomfortable. We know what we know, and our formulas have been working just fine. What could possibly be new in fluid power? The laws of physics have not been changed, and it is unlikely some new laws have been discovered. So what will this new era bring to light that we don’t already know? It’s not that we need to learn new things. We simply have to think a little more deeply about the things we already know and have sometimes taken for granted.

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One of the most common misunderstandings about fluid power is the relationship between flow and pressure. It is hard to convince someone that increasing the pressure in a system will not increase the speed when the technician just finished increasing the pressure in the system and things are going faster. Most folks are unfamiliar with Daniel Bernoulli and his discovery that there is a relationship between pressure and flow when an orifice is involved. If the system in question has resistive flow controls, or even if it only has plumbing that functions as a restrictive orifice, increasing the system pressure, upstream from the restrictions, will increase the flow to the actuator. It was the increase

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in flow resulting from the increase in pressure that made things go faster. However, there is an inextricable relationship between pressure and flow that must be understood when we are talking about power transfer. Any fluid power designer is familiar with the rotary power formula P = p x d x N / K where P is power, p is pressure, d is displacement, N is RPM, and K is a constant. Using this formula, we see that there is an absolutely discrete relationship among the variables; for any given power requirement at a given RPM, there must be a discrete product of pressure and displacement. With a variable flow source, such as with a variable-displacement pump or an accumulator, an increase in pressure with a constant motor displacement, would cause an increase in RPM. A power-limiting pump is a variable-displacement pump set at a fixed pressure that varies its flow to match a power output. If this type of pump is used to drive a fixed-displacement motor under constant load, you could establish the motor RPM by the pressure setting of the compensator,


without the use of a flow control, according to the power formula. A change in speed would require a change in pressure. Let’s try it out: Get out your calculator or open up a spreadsheet and plug in the power formula. For power, put in 10 kW; for pressure, put in 20 MPa. Displacement will be 10 cc, and the K constant is 60,000. When we solve this for RPM, we get 3,000. Now, increase the pressure to 21 MPa. What do you get for RPM? That’s right. It drops to 2,857. It is true that there was a decrease in flow to reduce the speed, but it was responding to an increase in pressure. Wait a second! Are you telling me that an increase in pressure produced a decrease in flow? That’s crazy! Everybody knows that an increase in pressure will cause an increase in flow and therefore an increase in RPM, right? Well, apparently not. We set up the formula so that there is a constant power input. The formula requires a discrete relationship among the variables, and the only thing we allowed to change with the pressure was the RPM. An increase in the torque demanded an increase in pressure. With constant power, the only option was to slow the motor. A variable-displacement, pressure-compensated pump that is not power limiting will typically have a greater flow capacity than is

required by a fixed-displacement motor. The compensator will be set at a pressure that is higher than the maximum load requirement. If the load on the motor is constant, the speed of the motor can be controlled by a simple needle valve or a pressure-reducing valve. The needle valve confirms Bernoulli’s observation: a specific flow will be provided because of the constant pressure drop across the needle valve. A pressure-reducing valve confirms the power formula: constant power, RPM, and displacement require a constant pressure in order for the motor to have a constant speed. But, in this case, if the pressure setting of the compensator or the pressure-reducing valve is raised, there will be more flow and the speed of the motor will increase. If the load on the motor is reduced, there will also be an increase in motor speed. Very few applications have motors that have constant loads. If a constant speed is required from the motor under varying loads and/or with a varying flow and pressure source, a pressure-compensated flow control or a load-sensing system can be used. These are designed to provide a constant pressure drop, regardless of load or supply pressure, resulting in a constant flow and RPM at the motor. Exactly the same situation exists for linear motion. A power formula could be written:

"There is an inextricable relationship between pressure and flow that must be understood when we are talking about power transfer."

P = K x V x d2 x p where P is power, K is a constant, V is velocity in in/sec, d is diameter, and p is pressure (the constant includes solving for the area). Again, we see that there is an absolutely discrete relationship among the variables; for any given power requirement at a given velocity, there must be a discrete product of pressure and area. We’ll give this a try: P will be 10 HP, K is 0.000119, d is 2 inches, and p is 2000 psi. Who wants to solve for V? Ok, what did you find? That’s right: 10.5 in/sec. Now, increase the pressure to 2200 psi and what happens? The velocity drops to 9.5 in/sec. So, again

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we see that, given a constant power input, an increase in pressure will result in a reduction in speed. The point is, we need to think a little more deeply about our power formulas. In future articles, we will look at making velocity, angular or linear, the constant. With both hydraulics and pneumatics, the variable power source is always at a higher pressure than is required by the load. If the pressure were only that induced by the load, it would be a static situation. Directing the high pressure of the flow source directly to the actuator would cause the actuator to accelerate until the discrete relationship within the variables is satisfied, or, in the case of pneumatics, until the critical backpressure is reached. To prevent this, flow controls are installed. These flow controls add an additional restriction, producing a pressure drop so what enters the actuator satisfies the power formula. In a pneumatic system, both the flow control and the pressure-reducing valve (regulator) restrict the rate of flow to or from the actuator. Of the two, only the regulator reduces the energy consumed. The regulator limits the total number of air molecules that enter the actuator while the flow control only limits the rate of flow until the actuator stops. Once the actuator stops, the flow control allows more molecules in until the actuator reaches line pressure.

In hydraulic systems, neither the flow control nor the pressure-reducing valve limits the energy consumption. Potential energy has been given to each unit of relatively incompressible hydraulic fluid. When that energy is greater than what is needed by the actuator, the energy must be removed to prevent acceleration. Both the flow control and reducing valve remove the excess energy by extracting the energy as heat. So, back to “Flow Means Go.” There is no “Go” with flow unless it is accompanied with sufficient pressure. There is too much “Go” when flow has more than the required pressure. If you were to ask most any hydraulic professional how to make a motor or a cylinder go faster, you would likely receive the answer, “Add more flow.” This is normally my answer, too, especially when doing training in basic fluid power. This is correctly based on our understanding of the relative incompressibility of hydraulic fluid. A fixed-displacement actuator, be it a motor or a cylinder, will require a certain volume of fluid to move a given distance. The rate of speed is determined by the flow rate to the actuator. We are so accustomed to this concept that we take for granted the need to toss away the excess energy supplied by the pump or accumulator. The energy loss is simply the cost of control.

We need to think differently. Instead of separating flow and pressure as two different entities, we need to combine them into a single energy unit. Much like in electricity, where the volt/amp is the energy unit, we need to think in terms of pressure/volume as our energy unit. When we think this way, we are closer to finding a way to use flow without the expense of pressure. We can determine energy requirements in terms of units of pressure/volume. We can understand the potential energy stored in accumulators and, hopefully, not be too willing to toss the excess away.

Dan Helgerson, CFPAI/AJPP, CFPS, CFPECS, CFPSD, CFPMT, CFPCC, is FluidPower Journal’s technical editor. He can be reachedat dan@cfpsos.comor by visitingwww. cfpsos.com. Stay tunedfor more articles in this series, andkeepthe conversation goingby visitingDan’s blog, Watts It All About, at www. fluidpowerjournal.com.

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NFPA UPDATES

NFPA Continues to Strengthen the Fluid Power Industry By Tricia Fulton, CFO, Sun Hydraulics Corp., 2016-17 NFPA Chairwoman of the Board

In June of this year, the NFPA Board of Directors held its annual strategic retreat where we discussed many of the challenges faced by the fluid power industry and what NFPA is and should do to help our members address them. It was an exciting and productive meeting for me, knowing that, as the new Chairwoman of the Board (NFPA’s first!), it would be my responsibility to shepherd the outcomes determined by the Board in our 2016-17 fiscal year. At the June meeting, the Board spent some time reviewing the latest information from our membership satisfaction survey and engaged in much discussion about the changing climate of our industry. Taking into consideration the significant strategic and program successes we’ve seen over the past year*, we worked on crafting a set of clear, high-level objectives—what we refer to as “ends” statements, because they describe the major ends or outcomes we wish to achieve. These objectives are: ƒƒ NFPA provides an effective forum for fluid power manufacturers, distributors, and suppliers to advance their collective interests. ƒƒ NFPA provides its members with timely and accurate industry statistics that support improved decision-making. ƒƒ NFPA provides opportunities and resources for its members to promote the unique strengths and inherent advantages offered by modern fluid power technology. ƒƒ NFPA fosters awareness and involvement of middle and high school students, helping them understand fluid power’s potential as a technology and as a career path. ƒƒ NFPA helps increase the number of technically trained people capable of integrating and applying fluid power and connects them to careers in the fluid power industry. ƒƒ NFPA supports universities in the development of fundamental fluid power knowledge and connects our industry to an increasing number of scientific and engineering leaders in our field. These statements represent the current strategic vision of the Association. They describe how we intend to fulfill our mission to strengthen the fluid power industry. The first three objectives represent our Association’s core strengths and member benefits. In Effective Forum, NFPA’s membership and conference attendance continues to grow, underscoring the importance of the inclusive forum we have built for networking, education, and coordinated action. In Industry Statistics, our portfolio of market information programs is stronger than ever, with a new, user-friendly toolkit to help our members make use of that information. And, the opportunities and resources we have built to help you Promote Fluid Power continue to multiply, with another record-breaking IFPE tradeshow quickly approaching. The second three objectives reflect our Association’s commitment to growing an educated fluid power workforce. Thanks to the unprecedented support of our NFPA Foundation donors, the programs we coordinate to expose Middle and High School Students to our industry, build educational capacity within 2-year tech schools to increase the number of Technically Trained People, and connect our members to an emerging workforce within Universities are reaching new heights of participation and effectiveness. As with any organization, challenges remain. For NFPA, these largely align with continued growth and sustainability of our mission and affiliated programs. Our productive partnership with the CCEFP is going through a critical time, as the upcoming year will be the first without any of the National Science Foundation funding that helped launch the CCEFP ten years ago. We highly value our relationship with the CCEFP and see its role as helping our industry connect with the universities that are developing the workforce we need for the future. I look forward to a very active year as your Chair. Please feel free to contact me through the NFPA office if you have any questions. I would strongly encourage your continued involvement in all of the activities of the NFPA. *Please visit http://news.nfpahub.com for success highlights from the 2015-16 NFPA Strategy Agenda. www.IFPS.org • September/October 2016 • www.FluidPowerJournal.com

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The staffers in the offices of the following Senators and Representatives were briefed on this subject when we met with them in February: Sen. Alexander (TN), Mackensie Burt (Mackensie_Burt@alexander.senate.gov) Sen. Baldwin (WI), Colleene Thomas (Colleene_Thomas@baldwin.senate.gov) Sen. Boozman (AR), Philip Moore (philip_moore@boozman.senate.gov), Jimmy Harris (jimmy_harris@boozman. senate.gov) Sen. Brown (OH), Jonathan McCraken (Jonathan_McCracken@brown.senate. gov) Rep. Cheri Bustos (IL), Lyron Blum Evitts (lyron.blum-evitts@mail.house.gov) Sen. Casey (PA), Kichelle Webster (kichekke_webster@casey.senate.gov) Rep. Charles Dent (PA), Dennis Petersen (dennis.petersen@mail.house.gov) Sen. Durbin (IL), Jasmine Hunt (Jasmine_Hunt@durbin.senate.gov) Sen. Feinstein (CA), Trevor Higgins (Trevor_Higgins@feinstein.senate.gov) Rep. Bill Foster (IL), Samantha Warren (samantha.warren@mail.house.gov) Sen. Franken (MN), Blaise Sheridan (Blaise_Sheridan@franken.senate.gov)

Your Help Needed

Funding for Fluid Power Research Takes Another Step Forward by Eric Lanke, NFPA CEO

Not too long ago, I wrote about NFPA’s day on Capitol Hill—when several NFPA members and I met with 20 or so Congressional offices to advocate for a new research program within the Department of Energy focused on fluid power in off-highway vehicles. The Good News: Language friendly to this new program was included in an appropriations bill passed by the U.S. Senate: “The Committee recognizes that the commercial off-road vehicle sector, including industrial, mining, and farm equipment, consumes over 2 Quads of energy per year and directs the Department to establish a dedicated activity to reduce the energy consumption of commercial off-road vehicles. The Committee recommends not less than $5,000,000 to support improving the energy efficiency of fluid power systems for commercial off-road vehicles.” The Bad News: The House version failed to pass, not because of the merits on this proposed program, but for other, politically motivated reasons. A conference committee is now working on a compromise bill that we believe will be passed later this summer or fall. If you’re interested in seeing DOE investment in this area, you are welcome to contact your representatives to express your support of the Senate language.

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Sen. Graham (SC), Virginia Boney (Virginia_Boney@lgraham.senate.gov), Scott Graber (scott_graber@lgraham. senate.gov) Sen. Grassley (IA), Kurt Kovarik (kurt_kovarik@grassley.senate.gov) Sen. Kirk (IL), Jon VanderPlas (jon_vanderplas@kirk.senate.gov) Sen. Klobuchar (MN), Anne Knapke (Anne_Knapke@klobuchar.senate.gov) Sen. Schumer (NY), Oumou Ly (Oumou_Ly@schumer.senate.gov) Rep. Terri Sewell (AL), Rob Nuttal (robert.nuttal@mail.house.gov) Sen. Shelby (AL), Dayne Cutrell (Dayne_Cutrell@shelby.senate.gov) Supportive messages from constituents in these states and districts may be especially helpful at this point. Please reference the “Commercial Off-Road Vehicle Program at DOE” in the “Fiscal Year 2017 energy and water appropriations conference report” in your correspondence.


We have new logos for these Challenges and pages on the site that describe in detail what these great opportunities are, and how they can benefit teachers and students in a big way. Old friends can change...but many times they get even better.

Please check out the new site at http:// nfpahub.com/fpc/. If you have comments or suggestions, contact Lynn Beyer at lbeyer@nfpa.com or 414-7783364. (Special thanks to everyone who has supported NFPA Workforce Programs.)

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by Lynn Beyer, NFPA Director of Workforce Development Programs

I was moderately upset when Instagram recently changed its format. This social media site has been a friend to me, and it hurts to see an old friend that you love so much change! You will not mind the change at all when you see the new Fluid Power Challenge website. Part of our continued and growing focus on education and workforce programs, the site is bright, clean, and easy to navigate. Very soon we will also be launching a Facebook page to further engage and grow the community of Fluid Power Challenge participants. There are some other changes to our workforce programs as well. Great changes. These changes will bring a pathway for students to follow in order to find, learn, and get involved with fluid power as a career. How? The NFPA Fluid Power Challenge brand will now include three exciting Challenges: ƒƒ The Fluid Power Action Challenge – This is the current Fluid Power Challenge event for middle school students in which teams build their own fluid power mechanism and compete. ƒƒ The Fluid Power Robotics Challenge – This will be a scholarship to a high school senior who uses pneumatics in his or her FIRST® Robotics Competition robot to use in an engineering course of study. ƒƒ The Fluid Power Vehicle Challenge – Formerly the Chainless Challenge, this is a program that challenges college engineering students to redesign a traditional bicycle using hydraulics as the mode of power transmission.

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NFPA UPDATES

Registration Open for FPIRC 2016 October 10-12, 2016 • Hyatt Regency Minneapolis in Minnesota The Fluid Power Innovation and Research Conference (FPIRC), co-sponsored by the National Fluid Power Association (NFPA) and the Center for Compact and Efficient Fluid Power (CCEFP), is the premier conference for fluid power industry and academic research in North America. Conference presenters include industry practitioners and leaders, academic fluid power researchers, and students from around the world. Recommended attendees are fluid power engineers and technical leaders, human resource professionals, CTOs, and marketing personnel. At this year’s FPIRC, attendees can ƒƒ participate in a program of over 30 fluid power technical posters and presentations, including keynote talks on the workforce development continuum, wearable robots, and ways to revitalize the full potential of hydraulic system technology; ƒƒ listen to panel discussions on the role of start-ups in a healthy industry and external technology trends; ƒƒ meet one-on-one with fluid power experienced students in corporate/ student speed meetings; ƒƒ engage with members of industry during the corporate kiosk reception;

ƒƒ attend a post-event facility tour of UMN Research Labs and Cummins Power Generation or Eaton Hydraulics and MTS Systems; and ƒƒ opt to also attend 2016 ASME Dynamic Systems and Control Conference, held in conjunction with FPIRC from October 12-14, 2016.

Reserve Your Hotel Room To make Hyatt Regency Minneapolis reservations, please call 1-800233-1234 and refer to the NFPA / National Fluid Power Association’s FPIRC / Fluid Power Innovation and Research Conference.

Sponsorship Opportunities Show your support for fluid power education and research while raising your visibility at the event by sponsoring the 2016 Fluid Power Innovation and Research Conference. Contact Eric Lanke at 414-7783351 or elanke@nfpa.com with your sponsorship inquiries. Learn more about the conference and register at http://nfpahub.com/ events/conferences/fpirc/

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NFPA, IFPS MEMBERS EDUCATE DOE ASSESSORS ON FLUID POWER EFFICIENCY by Eric Lanke, NFPA CEO The U.S. Department of Energy maintains more than 20 Industrial Assessment Centers (IACs) around the United States—university programs where energy management engineering students perform no-cost assessments of industrial facilities and make recommendations for reducing their overall energy consumption. According to the data I saw when I attended an IAC directors meeting last year, these centers perform about 500 assessments annually, identifying $33 million in energy-saving recommendations each year. And up until recently, none of those recommendations had been focused on the more efficient use of the ubiquitous hydraulic and pneumatic systems that are in these plants. “They’re a black box to us,” one of the IAC directors told me at this meeting. “We see them operating in our facilities, but we don’t know how to determine if they’re operating efficiently, or what changes to recommend even if we could.” Game on, I thought. There are lots of experts in the fluid power industry who could teach the student assessors what to do and recommend in those situations, and, with the help and support of the International Fluid Power Society (IFPS), I was able to find two great ones. Earlier this year, two webinar presentations were given to IAC directors and their students across the country. Tom Blansett, CFPS, and formerly of Behco-MRM, presented “Increasing Energy Efficiency of an Industrial Hydraulic System,” and Jon Jensen, CFPPS, CFPECS, of SMC Corp. of America presented “Pneumatics Best Practices.” Both presentations provided the basic information engineers and technicians need to diagnose, correct, and maintain energy-efficient fluid power systems. Both presentations can be downloaded for local viewing on the IAC website (www.iacforum. org:8080/iac/webinars.jsp), which I would encourage you to do for your own education and training needs. They’re so good, in fact, that we’ve asked Tom and Jon to repeat their performances at the upcoming Energy Efficient Hydraulics and Pneumatics Conference, which will be held in conjunction with IFPE, March 8-10, 2017, in Las Vegas, Nev. The feedback from the IAC directors was quick and immediate. “Thank you,” they said. “Now our students have some idea what to look for and recommend when they encounter hydraulic and pneumatic systems in their assessed facilities.” But things won’t end there. Now that fluid power is on their radar screen, the students and their directors are going to need ongoing support for any technical questions they may have. And the plants that receive the improvement recommendations are going to need suppliers and vendors with the expertise to implement those changes. This new opportunity is available to any interested company. If you’re willing to serve as a non-compensated resource for IAC students and to have your firm listed in the referral directory given to companies that receive an IAC assessment, please contact me at elanke@nfpa.com. We’ll need a contact name and information, as well as a short description of your company, the regions it serves, and the specific areas of expertise. www.IFPS.org • September/October 2016 • www.FluidPowerJournal.com

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INTRODUCTION TO HYDRAULICS FOR INDUSTRY PROFESSIONALS

ENERGY-SAVING CONSIDERATIONS and Fixed Pump Unloading

An energy-saving design strategy must be applied in designing a hydraulic system.This design strategy considers many energy-saving issues that minimize the wasted energy during the operating and idle conditions of the system (that whole topic will be contained in another textbook of this series). For an introductory level, this article will focus on an essential energy-saving issue, which is unloading a pump during the system’s dwell time or idle conditions.

By Dr. Medhat Khalil, Ph.D., CFPHS, CFPAI, Milwaukee School of Engineering

Unloading a Pump that Drives a Single Actuator Fig. 1 shows the use of a tandem or an open-center directional valve to unload the pump. This simple solution is adequate for a pump that drives a single actuator. When a tandem-center valve is used, the pump is unloaded and the load is held firmly. When an open-center valve is used, the pump is unloaded and the load is free to move.

Unloading a Pump that Drives Multiple Actuators If a fixed-displacement pump is used to drive multiple actuators in parallel, a combination of tandem and/or open-center directional control valves can’t be used. That is because, as shown in Fig. 2, the oil is still able to escape to the tank through the central position of the other directional control valve (DCV). Therefore, for a fixed-displacement pump that is used to drive multiple actuators in parallel, the pressure ports of the DCVs must be blocked. So the valve should be of a closed-center or float-center type. Fig. 3 shows a fixed pump that drives two actuators in parallel using a closed-center valve and a float-center valve. A 2/2, normally open DCV is used separately to unload the pump. Actuating the unloading valve can be electrically synchronized with the actuation of any of the other directional valves.

Fig. 1: Unloading a pump that drives a single actuator

0.04 bar Fig. 3: Unloading a pump using a separate DCV

Fig. 2: Improper combination of tandem and open center valves in parallel

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Fig. 5: Unloading a pump using a pressureunloading valve Fig. 4: Unloading a pump using a two-stage PRV with unloading feature

Fig. 6: Unloading a fixed pump in an opencenter system in mobile applications

Unloading a Pump by a Pressure Relief Valve (PRV) with an Unloading Feature For large pumps, the previous simple methods of unloading the pump through a direct-operated directional control valve may not be adequate. Therefore, as shown in Fig. 4, a pilot-operated PRV with a built-in unloading valve offers a solution to unload large pumps. The built-in unloading valve can be selected either normally open, i.e. the pump is normally unloaded, or vice versa, depending on the operating condition of the machine. The idea is to be certain that the pump is unloaded whenever the fluid is blocked by all of the DCVs.

Unloading a Pump by a Pressure-Unloading Valve A pump can be unloaded using a pressure-unloading valve, as shown in the Hi-Lo circuit in Fig. 5. In this system, both pumps are joined to advance the cylinder rapidly in the early stage of the cylinder’s extension stroke. When the cylinder touches the work piece and gets into the pressing phase, pressure will increase accordingly. When the system pressure increases, it closes the check valve so that the outlet of the large pump is blocked. Simultaneously, the increased pressure opens the pressure-unloading valve for the large pump to flow back comfortably to the tank. Fig. 7: Unloading a fixed pump in a closedcenter system in mobile applications

Unloading a Pump in Mobile Applications A hydraulic system in a mobile machine could be constructed as a closed-center system or an open-center system. In an open-center system, shown in Fig. 6, when all the spools in the control block are in their center positions, the pump will be unloaded through the open center line. In a closed-center system, a fixed pump can be unloaded by any way similar to industrial applications. In the system shown in Fig. 7, the pump is unloaded by a solenoid-operated, separate 2/2 directional valve that is assigned as an unloading valve. Actuation of such an unloading valve can be synchronized with the actuation of any of the other spools.

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FEATURES

OPEN VERSUS CLOSED CENTER SYSTEM

Design Complexity

• An open-center system is simple in design and does not require a special arrangement to unload the pump. • A closed-center system requires either a variable pump or an additional method to unload the pump if it has a fixed displacement.

Cost

• If both systems have the same number of sections, the opencenter one will be less expensive.

Energy Saving

• In idle conditions of an open-center system, the pump wastes energy continuously through the consecutive sections due to the pressure drop through the sections. • In idle conditions of a closed-center system, the pump is either unloaded or near zero displacement with limited energy loss.

Pressure Readiness & Response

• In an open-center system, by shifting one of the spools, the pump takes a little time to build pressure against the external load. • In a closed-center system, the pressure is ready at each of the load ports so that the response of the system will be faster.

By Dr. Medhat Khalil, Ph.D., CFPHS, CFPAI, Milwaukee School of Engineering

Table 1 summarizes the main features of both systems. This chapter excerpt is taken from the book, Introduction to Hydraulics for Industry Professionals, Hydraulic Systems Volume 1, 1st edition. Dr. Medhat Khalil, Ph.D., CFPHS, CFPAI, is director of professional education and research development, Applied Technology Center, at the Milwaukee School of Engineering (MSOE). This book is distributed for free to MSOE seminar attendees and sold separately at www.compudraulic. com (10% discount code FPJ2016 for Fluid Power Journal readers).

Table 1: Open-Center System versus Closed-Center System in Mobile Applications

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CIRCLE 442


ECONOMIC REPORT

British Pound to One U.S. Dollar

Global Manufacturing Update BY CHAD MOUTRAY, Ph.D., CBE, Chief Economist, National Association of Manufacturers

July 18, 2016 – It has been a momentous couple of weeks in the global economy, spurred by a tremendous amount of volatility in financial markets following the United Kingdom’s vote of June 23 to leave the European Union (EU). In the aftermath of that election, equity markets around the world moved lower and international investors flocked to “safe havens” – including the United States – to park their money. This has pushed 10-year Treasury yields to historic lows, which should benefit homeowners, many of whom are taking advantage of the opportunity to refinance or purchase a new home. But, it also pushed the U.S. dollar higher. Indeed, the dollar appreciated 14.5% versus the British pound in the two weeks following the U.K. election, with the pound falling to its lowest level since 1985. Since then, things have calmed down a bit, helped along by the selection of a new U.K Prime Minister Theresa May, who took over on July 13. In addition, the surprise decision by the Bank of England this morning to keep rates unchanged sent the pound higher. All told, the British pound has now appreciated around 10% over the past three weeks, as of this morning. Interestingly, the rest of Europe was more upbeat in the latest Markit Eurozone Manufacturing PMI, which increased to its highest reading since December. The survey was conducted from June 13 to 23, which means that all responses were collected before results from the British vote to leave the EU were known. With that in mind, it will be interesting to see how sentiment has shifted post-election, both in Britain and the Eurozone. Despite the more-positive sentiment survey readings, Eurozone industrial production fell 1.2% in May, nearly offsetting the 1.4% gain seen in April. On a year-over-year basis, industrial production grew 0.5%, a very modest pace. Nonetheless, retail sales were stronger, and the unemployment rate fell to 10.1%, its lowest level since July 2011. While the currency impacts of the British EU exit, or Brexit, have been largest for the U.K., it exacerbates a strong-dollar trend that continues to challenge manufacturers in the U.S. Indeed,

the trade-weighted U.S. dollar index against major currencies from the Federal Reserve Board has increased nearly 20% since the end of June 2014. That continues to represent a significant appreciation in the dollar in a twoyear period, making it more difficult for manufacturers to sell abroad. Using non-seasonally adjusted data, U.S.-manufactured goods exports totaled $431.45 billion year-to-date in May, down 7.5% from $466.49 billion in May 2015. Moreover, exports were lower in the top five markets for U.S.-manufactured goods: Canada, Mexico, China, Japan, and the U.K. On the positive side, the J.P. Morgan Global Manufacturing PMI edged higher in June, expanding ever so slightly after being stagnant in May, and we have seen some progress in terms of the number of key markets experiencing manufacturing growth. Nine of the top 15 markets for U.S.-manufactured goods had expanding levels of manufacturing activity for the month, up from five in April and eight in May. Yet, there were five countries experiencing contractions in June – all with long-running challenges. Those markets were Brazil, China, France, Hong Kong, and Japan. We will get new data on Chinese industrial production, retail sales, and fixed-asset investment on July 15, but recent data have reflected a continued deceleration in activity. At the same time, the Caixin China General Manufacturing PMI has now contracted in 18 of the past 19 months. Meanwhile, Brazil – which will be in the international spotlight next month with the Olympics – remains mired in a deep recession. In Brazil, first-quarter real GDP was off 5.4% yearover-year, with industrial production down 8.9% over the past 12 months in May, using seasonally

adjusted data. Meanwhile France remained the weakest economy in the Eurozone, contracting for the fourth consecutive month on weaker orders and production. Trade policy issues continue to be front and center in the public discourse, which the NAM is addressing through multiple avenues. Efforts continue to move forward the Trans-Pacific Partnership (TPP) and a fully functioning Export Import (Ex-Im) Bank on the Hill, along with gearing up for the new Miscellaneous Tariff Bill (MTB) process. Talks on the Transatlantic Trade and Investment Partnership (TTIP) negotiations and the environmental goods talks continue this month. A new World Trade Organization (WTO) case against China’s market-distorting export taxes on nine raw materials was launched this week. Manufacturers are also watching closely new developments on direct flights to Cuba and on conflict minerals in the United States and the EU. Excerpt reprinted with permission. For the full report, which includes links to the press releases used to compile this information, visit www.nam.org.

The National Association of Manufacturers (NAM) represents small and large manufacturers in every industrial sector in all 50 states. For more information, visit www.nam.org.

www.IFPS.org • September/October 2016 • www.FluidPowerJournal.com

51


FIRE-RESISTANT HYDRAULIC FLUIDS: Cost vs. Benefits BY PETER SKOOG, QUAKER CHEMICAL CORP.

A large automotive components manufacturer had a series of fires on its hot stamping lines—all caused by oil from ruptured hoses or leaky couplings that ignited when the oil came into contact with the hot metal being formed. In 2012, a particularly bad fire injured workers and caused 12 days of downtime, resulting in £5.3 million in damages from lost production and repairs. After assessing all the options—including changes to the sprinkler systems and equipment design— management concluded the safest and most costeffective approach would be to replace the highly flammable mineral oil with a synthetic, water-free hydraulic fluid (HFD-U). This conversion was a significant outlay—approximately £70,000. So why did management believe avoiding future fires was worth that much additional expense?

52

Mineral Oil—Large Operators Say Too Much is at Risk Today, in manufacturing operations that pose a risk for fire or explosion, most large-scale manufacturers have already replaced mineral oil with fire-resistant hydraulic fluids. Even though these fluids can cost anywhere from two to four times as much as mineral oil, the economics are sound for these producers because with mineral oil, there is simply too much at risk. Fires not only cause an unsafe workplace; they also damage the manufacturer’s bottom line and reputation. Fires can cause ƒƒ Loss of capital due to loss of production and costly repairs (hoses, seal, and even full equipment replacement) ƒƒ Loss of ability to deliver components, which can result in diminished customer trust in a company’s ability to supply parts on time ƒƒ Injury or loss of life

Fluid Type

Mineral Oil

So when these larger, global producers decide to convert, they consider this wide range of issues. While product price is a factor, it’s only one of many. A great deal of consideration goes to “soft” issues that help uphold the company’s brand and reputation—including their commitment to customers, employees, the environment, and shareholders.

All Manufacturers Should Take a New Look Many manufacturers are experiencing a weakened economic environment. So discussions on spending more on anything, including fire-resistant hydraulic fluids, are usually not at the top of anyone’s list…unless there is a fire. A fire can be devastating to a producer, and even more so in these difficult times. Waiting until there is a fire to review fluid options is not a wise choice. And because the economics, regulations, and technologies related to hydraulic fluids are always changing, it’s best to evaluate hydraulic fluids peri-

HFA

HFC

HFD-U

Fire Risk

High

Low (due to high water content)

Low (due to high water content)

Low

Max Operating Pressure

5,000 psi

Requires special components

3,000 psi

5,000 psi

Relative Cost

$ to $$

$

$$ to $$$

$$$$$

Waste Treatable

Fully

Sometimes

Not Treatable

Fully

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odically, reviewing all the issues to determine if converting to a fire-resistant fluid makes sense for the facility.

How to Choose—There’s No One Right Answer Globally, there are two types of fire-resistant hydraulic fluids that are dominant in high-temperature operating environments: water glycols (HFC) and polyol ester (HFD-U)-based fluids. The relative benefits of each technology are different for each situation. Every company, every facility has a different set of demands to respond to—demands placed by regulators, customers, and the economy. A supplier with broad experience in a wide range of facilities and processes can help the producer explore possibilities and aid in the decision process. Tables 1-3 include three short examples of decisions customers made about their fire-resistant fluid technology after thorough analysis. When evaluating hydraulic fluid options, it is important for the manufacturer to pull together an internal team of stakeholders so all business issues can be considered and brainstormed. Within some companies, silos develop that impede the right overall decision. Each department has a specific focus, such as ƒƒ Safety and human resources: the lowest risk fluid ƒƒ Maintenance department: the fluid for higher productivity ƒƒ Waste treatment department: the best fluid to reduce waste treatment costs and surcharges ƒƒ Operators: the least expensive fluid For a thorough evaluation, a qualified supplier will help unify and support a 360-degree view of all the issues (Table 4). Preferably, this supplier will understand the specific processes and all the goals for the customer’s bottom line. A good supplier should be able to present several recommendations—each with pros and cons. Ultimately it is up to the customer to decide how to balance the benefit/cost equation. At Quaker Chemical, here is how we approach and evaluate hydraulic fluids: 1. We start by walking through the full process. We look at the hardware, layout, pressures, and environment. 2. We analyze the equipment: the OEM recommendation, operating pressures, cleanliness, processing speed, and load demand.

Table 1: Auto Components Manufacturer Looking for Process Improvements Conversion/ Decision

Switch from a water glycol (HFC) fire-resistant hydraulic fluid to QUINTOLUBRIC® 888 series polyol ester, a water-­‐free, synthetic (HFD-­‐U) hydraulic fluid

Industry/Process

Die casting for auto components

Deciding Factor

Good fire resistance, but unacceptable pump wear and poor component life.

Result After Conversion

Reduced pump wear by 91% (over 3,000 hours), and increased seal life by 250%. Additional process improvements were recognized with reduced pump and motor noise, and eliminated the required time and resources for fluid adjustments.

Table 2: Long Bar Manufacturer Looking for High Throughput Conversion/ Decision

Switch from mineral oil to a water glycol (HFC) fire-resistant hydraulic fluid

Industry/Process

Hot forging for long bar products

Deciding Factor

Plant gets paid by how many tons they can produce a month. If they have a leak, they don’t want to shut down for maintenance, therefore their fluid usage is high and synthetics would be too expensive.

Result After Conversion

Fires were eliminated. There was no decrease in component life. Based on the operating environment, a water-based technology improved worker safety, protected production, and met budget targets

Table 3: Die Caster Looking to Reduce Wastewater Surcharge Conversion/ Decision

Switch from a water glycol (HFC) fire-resistant hydraulic fluid to QUINTOLUBRIC® 888 series polyol ester, a water-­‐free, synthetic (HFDU) hydraulic fluid

Industry/Process

Die casting engines for auto industry

Deciding Factor

New regulations/surcharges for Biochemical Oxidation Demand (BOD) in facility effluents.

Result After Conversion

Because polyol ester fluids are lighter than water, they can be removed from wastewater streams by skimming. If they become emulsified with water, they can be removed using normal wastewater treatment techniques. Therefore, die casters were able to reduce or eliminate government surcharges.

3. We examine the fluids: the current fluid and usage compared to similar customers. 4. We check out the wastewater: the geographic location and proximity to metro area. We then proceed to onsite or outside, regulations, and current costs/surcharges. 5. We analyze conversion. This can be from mineral oil to water glycol, which is a longer process, involving draining, flushing, and refilling. The mineral oil to HDF-U conversion is a shorter process of topping off, draining, and refilling. There is no need to flush the system.

6. Finally, we suggest the best options for hydraulic fluid type and a specific product.

For more information Peter Skoog is technical manager – fluid power and grease, for Quaker Chemical Corp., a global provider of process fluids, chemical specialties, and technical expertise to a wide range of industries, including steel, aluminum, automotive, mining, aerospace, tube and pipe, and cans. Visit www.quakerchem.com.

www.IFPS.org • September/October 2016 • www.FluidPowerJournal.com

53


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ADVERTISER INDEX Company.....................................................................................................Page......... Circle  ALA Industries Ltd......................................................................................... 23.............475  BrassFittingsWorld.com................................................................................ 20.............458 BuyFittingsOnline.com..................................................................................... 46.............444 CFC Industrial Training .................................................................................... 43.............439 Clean Filtration U.S.A........................................................................................ 36.............433  Clean Filtration U.S.A.................................................................................... 19.............457 Clinton Industries............................................................................................. 28.............427 Clippard Instrument Lab Inc......................................................................... CIV.............447  Clippard Instrument Lab Inc....................................................................... 37.............480 Custom Manifold Systems (CMS)................................................................... 39.............434  Custom Manifold Systems (CMS)............................................................... 21.............465 Cyber-Tech Inc................................................................................................. 35.............431  Cyber-Tech Inc............................................................................................. 22.............471  Cyber-Tech Inc............................................................................................. 37.............481 Eaton Filtration................................................................................................. 45.............440  Eaton Filtration............................................................................................. 22.............470 Evonik Oil Additives.........................................................................................CII.............412 Flange Lock...................................................................................................... 50.............442  Flange Lock.................................................................................................. 18.............449 Flaretite Inc....................................................................................................... 39.............435  Flaretite Inc................................................................................................... 24.............479 Flow Ezy Filters Inc............................................................................................ 50.............445  Flow Ezy Filters Inc........................................................................................ 18.............450 Fluidyne Fluid Power.......................................................................................... 9.............417  Fluidyne Fluid Power.................................................................................... 21.............463  Fluidyne Fluid Power.................................................................................... 37.............482 Gefran Inc........................................................................................................ 25.............424 HAWE Hydraulik.................................................................................................. 3.............414  HAWE Hydraulik............................................................................................ 37.............483  Heavy Motions Inc....................................................................................... 37.............484  Hercules Sealing Products.......................................................................... 18.............452  Hercules Sealing Products.......................................................................... 21.............464  Hercules Sealing Products.......................................................................... 20.............460  Hercules Sealing Products.......................................................................... 22.............469  Hercules Sealing Products.......................................................................... 23.............474  Hercules Sealing Products.......................................................................... 24.............478 Honor Pumps U.S.A.......................................................................................... 46.............441  Honor Pumps U.S.A...................................................................................... 20.............461 Hydraulex Global............................................................................................. 13.............419  Hydraulex Global - Metaris.......................................................................... 38.............487 Hydraulics Inc................................................................................................... 42.............438  Hydraulics Inc............................................................................................... 19.............455 IFPE 2017............................................................................................................ 7.............416 Inserta Products............................................................................................... 26.............425  Inserta Products........................................................................................... 19.............456  Inserta Products........................................................................................... 22.............472 La-Man Corp.................................................................................................... 27.............426  La-Man Corp................................................................................................ 38.............485 Lubriplate Inc..................................................................................................... 5.............415  Main Manufacturing Products Inc.............................................................. 20.............462  Main Manufacturing Products Inc.............................................................. 38.............486  Marzocchi Pumps........................................................................................ 23.............476  MOCAP INC................................................................................................. 21.............467 MP Filtri USA Inc............................................................................................... 17.............422 MP Filtri USA Inc............................................................................................... 29.............428 MP Filtri USA Inc............................................................................................... 47.............443  MP Filtri USA Inc............................................................................................ 18.............448  MP Filtri USA Inc............................................................................................ 38.............488  Oil-Rite Corp................................................................................................. 20.............459  Oil-Rite Corp................................................................................................. 22.............468  Oil-Rite Corp................................................................................................. 38.............489 Peninsular Cylinder Co. Inc............................................................................. 24.............423  Peninsular Cylinder Co. Inc......................................................................... 18.............451 PHD Inc............................................................................................................. 41.............436  PHD Inc......................................................................................................... 23.............473  PHD Inc......................................................................................................... 38.............490 Power Valve U.S.A............................................................................................. 42.............437  Power Valve U.S.A......................................................................................... 21.............466 Rotor Clip Company........................................................................................ 11.............418  Rotor Clip Company.................................................................................... 39.............491 SC Hydraulic Engineering Corp....................................................................... 36.............432  SC Hydraulic Engineering Corp................................................................... 19.............454 Schmalz Inc...................................................................................................... 14.............420 Spectronics Corp............................................................................................. 15.............421 Sunfab North America..................................................................................... 31.............429  Super Swivels............................................................................................... 39.............492 VEST Inc........................................................................................................... CIII.............446 Yates Industries Inc............................................................................................ 1.............413  Yates Industries Inc....................................................................................... 19.............453  Yates Industries Inc....................................................................................... 39.............493 Youli Hydraulic Industrial Co. Ltd..................................................................... 31.............430  Youli Hydraulic Industrial Co. Ltd................................................................. 23.............477

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CIRCLE 446


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CIRCLE 447

FPJSO16  

September/October 2016

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