Fluid Power World April 2018

Going soft on grippers p. 46

Mobile hydraulic contamination control p. 54

OTC Show Preview p. 60

FPTC Preview p. 64

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April 2018

Hydraulic hybrid

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FluidLines

Boston Dynamics talks fluid power, 3D printing at IFK

No Kinks No Hose Twisting

More than 650 fluid power manufacturers, users and academics came to Aachen, Germany last month to talk about the future of hydraulics and pneumatics technology at the 11th IFK.

Aaron Saunders, VP of Engineering of Boston Dynamics gave a memorable keynote address. Boston Dynamics is the Massachusetts dynamo of a company that even many non-engineers know about, due to the company’s famous YouTube videos that feature bipedal and animal-like robots that jump, run, balance and even do backflips.

Saunders talk focused on building “the world’s most dynamic” humanoid robot—the famed Atlas, which has been through a redesign in recent years.

Saunders noted that Boston Dynamics is a very small company, with only 100 engineers. For the last 15 years, he said that his team has been focusing on basic principles of the mechanics of the locomotion of robotics. Their goal has been on changing people’s idea of what robots can do.

“I’m always asked, ‘What’s the purpose? Are you making any money with this?’ The answer is no,” Saunders said, to laughs from the audience.

“This robot’s [purpose] is really to drive innovation inside our group, to push us to understand how to marry controls on complex machines. It is also to create an impression of what robots can do. As we move toward the future, we’re getting closer and closer to when we’re going to turn these things into products.”

People also ask Saunders why they are making robots perform tasks such as making them jump. He explained that it forces his team to face a lot of pragmatic problems. In tasks such as jumping, there is a lot of coordination happening—in the upper body, in the legs and the feet. His videos showed the robot’s hands and arms moving to better stabilize itself, and its legs wobble when it landed on soft ground, far different than laboratory conditions.

This is on purpose, he said. “The other thing we do with a lot of the robots at Boston Dynamics that’s kind of unique is we put them out in the real world. Robots in their history have almost always been in the lab environment.”

“In these environments, the robots have to autonomously navigate the terrain,” he said, as another video showed a robot walking up an uneven set of stone steps in a parklike setting. “The only inputs that this robot is getting right now from the operator are simple joystick commands, like go forward, go left or right, and everything else comes autonomously from the control system.” (continued on page 4)

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4 • 2018

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FluidLines (continued from page 2)

Evolution of Atlas The journey that Boston Dynamics took in getting to this robot did not happen overnight. They started in 2009, literally sawing one of their quadrupeds in half to make an early biped robot, as they worked on a government project that used pneumatics. This robot was tethered for power and cooling.

“In 2012, there was a big competition started in the U.S. to use mobile robots to use in disaster response scenarios, and the government asked them to build 10 robots to give to universities to learn how to access these difficult trends,” he said.

Boston Dynamics used a lot of off-the-shelf components to put this hydraulic robot together, which was a 2-m tall robot that was self-contained and weighed nearly 200kg.

“In 2015, we got the opportunity— when we were acquired by Google—to really look inside and focus on things that we thought were important. We used the opportunity to redesign this humanoid robot from the ground up, and we ended up with a robot that’s very similar. It has all the same strength and range of mobility.”

This newer Atlas model is about 1.5 meters tall and weighs 80 kg. It has an increased strength density to near human levels, is completely power autonomous (running between 30-60 minutes, depending on what it is doing) and has 28 degrees of freedom.

“Cramming 28 active degrees of freedom that all do force control, position control, and high bandwidth into a small machine is actually quite challenging,” Saunders said.

Valves were a problem to source.

They found, as their scale got smaller and smaller, and moved down to the human scale, there really weren’t many choices to purchase a high-performance servovalves that they could use to do control. So, they developed their own, 4

FLUID POWER WORLD

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4 • 2018

which features multiple modes, for traditional servo, braking (negative work) and coasting (chamber to chamber). The valve, he said, has a fast response time and extremely low bypass leakage.

Help from additive manufacturing 3D printing technology has also been key to this version of Atlas.

“When we started the program, I’d read a lot of glossy magazine ads about how 3D printing was here. You could use it, you could print and go. That’s not quite true, but it is a very promising technology and it’s evolving rapidly,” Saunders said.

The robot’s leg makeup was, he said, “probably our biggest undertaking. We learned a lot of lessons … we integrated the structure, the manifold and the fluid routing and actuator cylinders all into one structure.”

“We were able to reduce limb inertia significantly, which is a big deal for a walking robot—most of the power in the system goes to swinging the legs through the air and accelerating and stopping them. You do very little work on the world when you’re a biped and you’re walking—you’re actually very efficient.

But you need a lot of power to swing legs, especially when they’re heavy, so this [reduction] was a big deal,” he said.

“We have a saying in our company called the bleeding edge. A lot of people talk about leading edge technology and the leading edge for us is when you’re going too far. The leg was very challenging because there was a lot of stuff integrated into it. Just finding a company to hone an actuator cylinder in a 3D printed material that had never been qualified before is a massive challenge. The number of close processing steps you have to go through as opposed to traditional machining really started to erode some of the benefits. In the end, we still saw that benefit in the inertia, but the effort to get this part out was quite significant,” Saunders said.

Similarly, the HPU uses 3D printing to achieve a lot of efficiencies.

“It’s approaching a kilowatt per kg of density, it’s pretty scalable,” he said.

“It sits in the center of the robot. It has everything it needs to collect electrical power and put hydraulic power out … All the homeostasis, sensing, filtration, dump valves, everything we need for the power plant is integrated into a printed part.

This lets us wrap everything really tightly around the reservoir—and uses empty space that’s otherwise not used.”

Atlas’ manifold has 18 valves, which service the upper body of the robot.

“This is where we are getting close to a sweet spot in printing,” Saunders said, “so we can make very organic structures and minimize pressure drops—get rid of a lot of excess components. It’s kind of exciting, the things that can be done in printing manifolds.”

But, he reiterated, he wants to see component manufacturers come forward and expand their offerings for uses like this.

“For us, I think one of the big things is the availability of small components. I would love to be able to come to a group like this and find more components on the human scale for mobile applications,” Saunders said. “Developing that valve was really fun, but we’re a robotics company— and we’d like to do more robotics and less component development. So, finding places that work with people to develop these small components on the timescales that are relevant is an area that it’d be great to see more of.”

FPW

Paul J. Heney VP, Editorial Director pheney@wtwhmedia.com

On Twitter @DW_Editor

www.fluidpowerworldonline.com

4/13/18 9:37 AM

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vol 5 no 2

April 2018

C ontents |

|

fluidpowerworld.com

•

4

•

2018

F E AT U R E S

INDUSTRIAL HYDRAULICS Hydraulic hybrid powers fuel-efficient tug Engineers take a novel, low-risk approach to marine propulsion.

PNEUMATICS Going soft on grippers

There’s a growing interest in nontraditional pneumatic end effectors that offer flexibility and a deft touch.

MOBILE HYDRAULICS Hydraulic system contamination: causes and solutions

Overlooking these common causes of hydraulic system contamination could mean catastrophic machine failure. Vigilance is key in maintaining a clean machine.

OTC PREVIEW A half-century of offshore insights

The Offshore Technology Conference marks 50 years, as it returns to Houston April 30 to May 3.

FPTC PREVIEW The Fluid Power Technology Conference returns to Milwaukee Now in its third year, the FPTC—slated for May 14 to 16 at MSOE’s Kern Center—boasts expanded session offerings for design engineers and MRO professionals.

38 46 54

46 D E PA R T M E N T S

02 FluidLines 10 Association Watch 12 Korane’s Outlook

60

14 Design Notes 27 Energy Efficiency 28 Distributor Update

64

30 Fundamentals 32 Maintenance 69 Products

71 Component Focus 72 Ad Index

A | S | B | P|E

A | S | B | P|E

American Society of Business Publication Editors

American Society of Business Publication Editors

Fostering B2B editorial excellence

ON THE COVER

With its hydraulic hybrid propulsion system, called Cat Marine Advanced Variable Drive, Caterpillar Marine is making efficient and innovative tuboat designs a reality.

6

| courtesy of iStock

FLUID POWER WORLD

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4 • 2018

2017 Regional

Fostering B2B editorial excellence

2017 Regional

PR INT

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APRIL 2018 • vol 5 no 2 • www.fluidpowerworld.com

EDITORIAL VP, Editorial Director Paul J. Heney pheney@wtwhmedia.com @dw_editor Managing Editor Mary Gannon mgannon@wtwhmedia.com @dw_marygannon Associate Editor Mike Santora msantora@wtwhmedia.com @dw_mikesantora

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FLUID POWER WORLD does not endorse any products, programs or services of advertisers or editorial contributors. Copyright© 2018 by WTWH Media, LLC. No part of this publication may be reproduced in any form or by any means, electronic or mechanical, or by recording, or by any information storage or retrieval system, without written permission from the publisher.

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ASSOCIATION WATCH

NFPA Minneapolis Regional Meeting

NFPA’s 2018 Minneapolis Regional Meeting is set for Thursday, May 10 and will be held at MTS Corp.’s Headquarters at 14000 Technology Drive in Eden Prairie, Minnesota.

MTS Corp. has been an active NFPA member since joining in 1993, and the NFPA is delighted they are putting out the welcome mat for this year’s Minneapolis Regional. Networking begins at 11:00 am, followed by lunch, a presentation, and optional tour of MTS facilities.

In addition to the casual networking and industry updates NFPA Regional Meetings are known for, the 2018 Minneapolis meeting will feature a special guest speaker from the Federal Reserve of Minneapolis. Joe Mahon, Regional Outreach Director, is an expert on the Ninth District regional economy—an area that covers Minnesota, North and South Dakota, Montana, and portions of Wisconsin and Michigan. Plus, Mahon closely follows agriculture, manufacturing, energy, mining, and other important end-use customer markets for the industry. He will also touch on labor trends in various markets. Mahon’s information will be timely and interesting, especially in today’s volatile economic climate.

As always, NFPA Regional Meetings are free and open to NFPA members and non-members alike. NFPA encourages its members to invite other business colleagues and feel free to share an invitation.

NFPA’s 2018 Minneapolis Regional Meeting is set for Thursday, May 10 and will be held at MTS Corp.’s Headquarters at 14000 Technology Drive in Eden Prairie, Minnesota. NFPA Regional Meetings are free and open to NFPA members and nonmembers alike.

FPW

NFPA | nfpa.com

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www.fluidpowerworld.com

4/13/18 9:48 AM

ASSOCIATION WATCH

DOE supports CCEFP universities in fluid power research The Department of Energy (DOE) has announced the funding of two new cost-shared projects: Purdue University (West Lafayette, Indiana) will receive $1.5 million to research a new architecture for fluid power systems in off-road vehicles that significantly reduces power losses and lowers energy consumption by 70%.

Additionally, University of Minnesota (Minneapolis) will receive $1.4 million to research a variable displacement motor for the off-highway market that reduces fuel consumption by 30% while increasing power density.

The department is also supporting $2 million in early-stage research on mobile fluid-power systems. Argonne National Laboratory (ANL), Oak Ridge National Laboratory (ORNL), and Pacific Northwest National Laboratory (PNNL) are developing high-performance fluid additives and coatings to improve efficiency, durability, and environmental compatibility of off-road hydraulic fluids and components.

This is part of the Energy Efficiency Research and Development for Fluid-Power Systems in Off-Road Vehicles Program. The program is administered by the Vehicle Technologies Office (VTO) in the Office of Energy Efficiency and Renewable Energy.

This level of government support for fluid power research is long overdue and critical to the ongoing health of the fluid power industry. These successes would not have been possible without a concerted effort by the CCEFP and our industry supporters.

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4 • 2018

FLUID POWER WORLD

11

4/13/18 9:49 AM

Ko ra n e ’s O u t L o o k Ken Korane • Contributing Editor

Trade wars and mega trends Americans like to think we’re the top dog in almost everything. But Germany is the world’s leading supplier of fluid power products, according to engineering association VDMA, well ahead of the U.S., China and Japan. Thus, comments

by Christian Kienzle, Chairman of VDMA’s Fluid Power Assn. and CEO of Argo-Hytos, deserve attention.

In a keynote at last month’s 11th IFK Conference on Fluid Power in Aachen, Germany, he struck an upbeat tone, noting the group’s sales increased 11% last year.

“These are incredible figures after five years of sluggish development in our industry.” And he predicts 6% growth this year, thanks to ongoing expansion in Asia and higher demand from Europe and the Americas.

But, he cautioned, politics has unsettled markets. “We are very close to a trade war between the United States, Europe and China. This would be disruptive for our industry” in ways no one can afford.

“We believe in free trade, and we have to be politically independent and demonstrate the strength of our industry compared to the Asian countries, Russia, and also America.”

Nonetheless, he’s optimistic about the future. “Let’s talk a little bit about the mega trends that we are facing,” Kienzle continued. “Population is one of the biggest challenges. World population will grow from 7.3 billion to around 10 billion people in 2050. That will mean dramatic changes for mobility, migration, and sustainable use of our natural resources.”

12

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4 • 2018

Christian Kienzle at the IFK fluid-power conference in Aachen.

An 80% reduction in CO2 emissions, according to the Paris Accord, would have an incredible impact on our daily life and will be extremely costly, said Kienzle. But it also offers a great opportunity for the fluid power industry to produce more-efficient products.

“People are moving into the cities.

We have to clean and maintain them properly,” he said. Transportation logistics and municipal services are areas where fluid power will contribute to this mega trend. “And, of course, the environment is extremely important. We have to use resources more efficiently.”

“One of the biggest trends is digitization.” It’s a big challenge but also an incredible opportunity, as it offers the possibility to link companies, develop platforms and technical networks, and offer a host of new services, he said. “So Industry 4.0 and fluid power, what does it mean?” For one, standardization is critical. “It’s sometimes dull work, but it’s extremely necessary. Data properties need to be standardized. We have to use

uniform semantics, so components and systems talk to each other, and machines can link to networks and use digitization in a proper way.”

Finally, he stressed the importance of the Fluid Power Research Fund that German firms unwaveringly support to the tune of nearly €1 million per year.

University researchers and industry partners work on pre-competitive projects in important areas like digitization and connectivity, said Kienzle. At the same time, students develop the knowledge and skills fluid power companies demand. “We all know how desperately we need young people in our industry. This is one of the most important future topics that we are facing down the road.” \FPW

www.fluidpowerworldonline.com

4/13/18 9:33 AM

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cobots DESIGN NOTES

Hydraulic unit expands beyond home factory Edited by Mike Santora, Associate Editor

The Green Hydraulic Power unit, designed by MJC Engineering, reports en-

ergy savings up to 70%. This earns users

MJC Engineering is a custom machine tool builder in Huntington Beach, Calif., specializing in metal-spinning machines for sheet spinning, flow forming, wheel spinning and others. MJC machines typically use large volumes of hydraulic power in operation.

About three years ago, the president at MJC, Carl Lorentzen, began investigating the configuration of the hydraulic units used on his company’s machinery. Lorentzen was interested in servo-pump technology, having read about its application in other industrial uses.

“We had looked at a variety of ways to improve the energy efficiency of our machines. Being a California company, there are substantial incentives offered here for documented energy savings in machine building and operations. Plus, I felt it was simply the right course of action to do our part in protecting natural resources,” said 14

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4 • 2018

energy credits from their home states.

Lorentzen. He also cited a recent incident where MJC changed insurance carriers and, as part of the company safety audit, sound levels were tested and the hydraulic power units were a concern.

All these factors caused a “light bulb moment” for the builder. MJC began serious investigation into the application of servo-pump technology to replace the constant motor operation on the main hydraulic unit of the machines, in a concerted effort to reduce energy consumption, noise and, owing to the smaller hydraulic reservoirs needed, the machine footprint.

www.fluidpowerworld.com

4/13/18 10:38 AM

When equipped with a high-level Safety Integrated PLC and other required components, the GHP is suitable for severe environments such as oil rigs, chemical processing equipment and other challenging work environment applications.

These definable upsides for MJC machine design caused considerable excitement for Lorentzen, who noted, “All these engineers had the same reaction I did and we began to rethink our hydraulic power units from the ground up.”

Lorentzen turned to his longtime supplier of CNC, PLC and drives technology, Siemens, for further assistance. A team led by Chris Britton, the Siemens sales manager for the region, assisted with various application engineering studies, energy and controls testing to affect the optimum design, all while working in concert with the MJC team.

Britton explained, “Carl’s company uses a wide variety of motion controls and components on their machine builds, including CNC, PLC, motors, spindles, power modules and our drive control chart (DCC) technology that allows configuring of all the control loop structures.”

A further advantage quickly emerged, as the Green Hydraulic Power unit (GHP) began to take shape. Little or no external cooling was required to dissipate the ambient heat of the unit. From the OEM perspective, MJC benefitted from the conceptualization, engineering and commissioning tools offered by Siemens during the build-up of the GHP units. Siemens SIZER software, for example, orchestrated the integrated data across the entire platform of drives technology, enabling the MJC engineering team to match the most suitable products to the specific requirements of the end user applications, with a drastic reduction in the engineering time on subsequent unit designs. M-CAD likewise enabled the importing of all motor specifications to match the requirements of each job.

Additionally, TIA Portal has faster commissioning, increases productivity and facilitates comprehensive data capture, which benefits both operations/maintenance personnel and the integration of the data into a “digital factory” mode, as the system’s condition monitoring and diagnostics can reside in the cloud or otherwise be networked to a controls communication stream. Depending on the drives technology selected, it is also possible for the end user to perform online configuration of the drives via their web server.

GKN Aerospace in Orangeburg, S.C. was the first customer for whom an entirely new MJC spinforming machine was built, using a

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DESIGN NOTES

Control panel with touchscreen operation and joysticks

Wireless panel operation for easy movement by operator

complete and now duly named Green Hydraulic Power unit. MJC’s Vice-President Per Carlson and his hydraulic engineer Jerry Wang designed the unit. An already documented result of the GHP unit onboard its machine, GKN has experienced nearly a 70% energy consumption savings, plus the quieter operation and smaller footprint.

Following this development, Lorentzen also realized the unit could easily be adapted onto any type of heavy hydraulic piece of equipment. Subsequently, he established Green Hydraulic Power Inc., which today functions as a free-standing enterprise.

As MJC electrical engineer and robotics manager Jose Machuca explained, “The GHP is a complete turnkey system with I/O options to run with any PLC, to control the power on virtually any type of hydraulicallypowered machine. We researched the variable speed drive hydraulics for over two years to devise the optimum solution on our current standard models, which comprise 15, 30, 55 and 80 kW units.”

Lorentzen further added, “Nobody is offering a closed-loop, engineered system like the GHP for integration onto a customer’s machine, with practically no impact on that machine’s design. It quickly became clear to us we had a real gem here, as GHP can be used as an OE component or retrofit onto an existing piece of machinery in the field. That includes practically every machine we’ve built ourselves.”

“We had a very dynamic interaction with the Siemens engineering team to make this unit come alive,” said Machuca. “We frankly didn’t know what to expect at the outset, but the results have been very pleasing so far. And we’ve only just begun.”

Further options under development for GHP include Scalance wireless control, kW torque setpoint on pressure, fail-safe compatibility, custom touchscreen and other monitoring and maintenance tools for operation and unit data transmission in an Industry 4.0 environment, over a Profinet industrial Ethernet protocol.

When equipped with a high-level Safety Integrated PLC and other required components, the GHP is suitable for severe environments such as oil rigs, chemical processing equipment and other challenging work environment applications.

FPW

WHAT Connect with thousands of DO engineering YOU design THINK? professionals

Siemens | siemens.com

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DESIGN NOTES

Hallite, MSOE partner for continued hydraulic seal testing Cold cylinder start-up test is the latest in Hallite’s third-party validation for the integrity of its sealing materials and designs.

Mary Gannon, Managing Editor After successful completion of a new test method in 2015 for assessing the amount of dirt and dust that enters a typical hydraulic system through the rod wiper, Hallite Seals decided to continue its partnership with the Milwaukee School of Engineering (MSOE) Fluid Power Institute.

Since the development of the rod wiper test, Hallite and MSOE have worked together to develop additional repeatable, comparative tests that allow Hallite to understand performance of existing and new prototype products. “MSOE does a lot of handin-hand work with Hallite,” said Russ Steinmmetz, MSOE Project Engineer.

Tests conducted to date include five specific areas: 1 insertion and break-away force testing for piston seals 2 frictional drag testing for rod seals at different pressures 3 deflection and compression testing for wear bands 4 cold cylinder start-up testing for rod seals 5 endurance testing for rod seals featuring a first-of-its-kind test chamber where 16 rod seals can be tested simultaneously

A look inside the closed-circuit cold-

The partners have recently concluded the first step in the cold cylinder start-up testing for rod seals’ performance, said Chuck White, Director of Commercial Development for Hallite. This test is different from standard cold-start tests, he explained, because most current tests may have the cylinder in a freezer but the oil may be warm at the start. Instead, the MSOE and Hallite test begins with the sub-Arctic temperatures one may find in Northern Canada, for example. The

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start test chamber at the Milwaukee School of Engineering’s Fluid Power Institute.

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A fluid leak is seen in the Hallite and MSOE-designed cold-start test chamber.

procedure requires cold soak of cylinders for 8-12 hours prior to cycling and the extremely low temperatures in the freezer effectively replicate conditions as if the machine was outside overnight. “Most of the current test standards do not replicate real-life cold-start conditions.”

MSOE developed a closed-loop/circuit system using accumulators to keep cold and warm oil separated in the application and to ensure consistent readings from test to test. This repeatable test chamber can reach –110°F (–80°C).

Hallite saw a need for this test when several cylinder customers came to its engineers with cold-start issues. So Hallite decided to use various cylinders available in the market with its rod seals to conduct side-by-side comparisons with different competitive profiles.

Cylinder pressure is just enough to move the rod, and cylinder speed is as slow as possible—down to ½ in./sec—to simulate worst conditions. As White said, these are “the worst possible operating conditions for a rod seal in cold conditions. When we start a cycle, if the temperature jumps more than 5°, we stop the test and let the oil cool down to the target test temperature.” Due to the oil viscosity being that of jelly at very www.fluidpowerworld.com

FPW_DESIGN NOTES 4-18_Vs4 MG.indd 19

low temperatures, ports in the hydraulic cylinder were adjusted to 1 in. in diameter to maximize the flow path of the stiff fluid.

Hallite’s rod seals are rated for –50°F in the catalog, which is considered Arctic conditions. The test is performed down to a maximum –65°F, as this becomes the limit for typical Arctic ISO 15 oils to remain fluid enough for a hydraulic system to operate.

White said that Hallite’s rod seals have performed quite well in the tests.

They have installed a camera in the freezer, which allows them to see how the seals perform under these harsh conditions. “With the camera, we can monitor the leakage during the test cycle,” White said. “So in real time, we can see what’s going on in there.”

Leakage is assessed by seeing oil build up on the rods. Using a visual leakage standard which employs a scale of 0 to 5—which has been adopted by many OEM hydraulic manufacturers—0 means there is no leakage. The 0-2 range is where you want to be performing as this there is no presence of oil dripping from the rod. At 3 there is a presence of intermittent fluid and non-falling beaded oil formation, and 4-5 is clearly a failure.

4 • 2018

FLUID POWER WORLD

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DESIGN NOTES

It’s unacceptable to be in that range, said White.

“For Hallite’s 605 asymmetrical U-cup, in tests to –65°F, we saw no leakage, so we’re at a 0. Hallite 621 saw a leakage rate of 1 at temperatures down to –65°F,” White said. “This indicates how both the seal profile and material will perform. If it falls within the acceptable range, this is what is to be expected in the field. This kind of testing is something that I don’t see our competitors doing.”

Hallite is in the process of testing several different rod seal profiles and materials to better understand how their products react in extremely cold conditions. “This allows us to be able look at what the true capabilities of our materials and profiles really are,” White said. “This will also allow us to develop

new materials and profiles, so we’re always ready to meet the market’s needs keeping in mind how these new products react in cold temperature conditions.”

This is just the first phase in this particular test. MSOE and Hallite plan to test with other types of Arctic fluids to understand how they perform in cold conditions with the seals. Hallite and MSOE will also be utilizing the fluid test facilities located in the Chase Commerce Center in Milwaukee. Featuring major hydraulic power capabilities, MSOE has specialized equipment for evaluating pumps, valves, motors, cylinders, tubes, filters, and winches in accordance with appropriate NFPA, ANSI, SAE, ISO and MIL standards.

According to Tim Kerrigan, director of the Fluid Power Institute, “Student involvement is a big part of what we

provide in these highly repeatable tests.

They work very hard to design tests that can do that.”

White added, “MSOE is great at developing test processes that are repeatable. For us to have third-party results, especially from MSOE which is so well-known in the industry, that’s powerful.”

FPW

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4/17/18 11:45 AM

DESIGN NOTES

HIC custom manifold eliminates leaks Edited by Mary Gannon, Managing Editor

By switching from a standard build with its hydraulic valves and manifolds, above, to a HIC custom build, left, from Daman Products, a machine builder was able to eliminate 39 leak points, streamline its design and assembly, and reduce costs by 11%.

Sourcing one-piece Hydraulic Integrated Circuit (HIC) Custom Manifold solutions from Daman Products helped a machine builder eliminate 39 leak points and reduce labor hours, number of components, and over-all costs by 11%.

Several years ago, Daman had a project where this machine builder specified standard components for a manifold consisting of six-station D05H manifolds, three-station D08H manifolds, an in-line pressure reducing body, and 24 stacked modules. This standard solution presented a number of problems, including: • 24 stacked modules • 48 leak points • 50 labor hours for assembly • Excessive maintenance costs • Excessive overall project costs 22

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The Daman team worked with its distributor to replace 25 components with a one-piece custom engineered manifold solution. Overall, the project ensured easy assembly and maintenance simplicity by reducing the number of required components from 25 to 1. It eliminated 39 leak points, streamlining the design from 48 to 9 leak points. In terms of construction, the custom HIC eliminated 30 hours of labor, dropping the build time from 50 to 20 hours, saving the machine builder 11% on costs from $27,000 to $24,000.

FPW

Daman | daman.com

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4/13/18 10:42 AM

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DESIGN NOTES

Bucher offers mini power pack Edited by Ken Korane, Contributing Editor

ini power pack Bucher’s UP40 m out 3 in. high measures only ab depends on and wide. Length specific motor. tank size and the

Engineers at Bucher Hydraulics have developed the UP40 mini power pack with the aim of bringing hydraulic control closer to the drive while providing a more-compact envelope.

Compared to other products on the market, the UP40’s dimensions have been reduced to a minimum, said company officials.

The external dimensions of 80 × 80 mm (3.15 × 3.15 in.) are basically defined by the extruded aluminum profiles that are used. The designers made significant efforts to keep within these dimensions while developing various hydraulic circuits. Any components that project outside that profile boundary, for example due to valve contours or accessories, are arranged to extend only on one side.

While the basic size is well defined, the power unit comes in various lengths, as a result of differing lengths of the electric motors and the various capacities of available tanks. The tank consists of a simple, 80 mm diameter extruded aluminum tube that mounts between the front and rear hydraulic control blocks.

The concept is based on a normal mini power pack consisting of an external gear pump driven by a dc electric motor. Oil flow depends 24

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4 • 2018

on pump displacement, speed of the electric motor, and the respective operating pressure. The gear pump can be unidirectional or reversible.

The power unit with a unidirectional pump consists of a standard front control block containing an adjustable relief valve and a check valve. These two cartridge valves are types typically required in hydraulic circuits and, exactly for this reason, the engineers decided to integrate them into the front control block.

This block is always installed, as it is also the connecting element between the hydraulic pump and electric motor.

From the front hydraulic control block, oil flows through a tube to the rear block, which incorporates the majority of the hydraulic circuit. Various circuit options are included in the company’s catalog.

The single-acting design has a rear control block incorporating a 2/2 seat valve and a pressure compensated 2-way flow control. This arrangement

www.fluidpowerworld.com

4/13/18 10:44 AM

With over 3 billion parts installed and failure rates less than 1 PPM, SFC KOENIG is recognized for excellence in sealing and flow control. The original inventor of the pre-assembled metal-to-metal seal solution, we offer: • a variety of sizes, materials and pressures • engineering support • faster installation & fewer errors • proven effectiveness in a variety of precision high-performance applications.

ction lets users Modular constru pump, motor, easily specify the controls tank and hydraulic plication. required for an ap

it can be The mini power un cylinder to combined with a motion create a compact actuator.

can also be supplemented with an integral emergency hand pump.

This version is often used for laterally mounted under-chassis wheelchair lifts.

Thanks to the very compact dimensions of the power unit and its quiet operation, it can also be mounted either inside or outside a vehicle cab (with appropriate safeguards in the case of outside installation).

A version featuring a 4-way spool valve with two or three spool positions for controlling double-acting cylinders is under development. This will also include the ability to fit a double pilot-operated check www.fluidpowerworld.com

FPW_DESIGN NOTES 4-18_Vs4 MG.indd 25

Contact us to review your application and request samples.

valve to minimize the effect of leakage that is a characteristic of spool valves.

In contrast, the unit for reversible pumps features a front control block with a double pressure-relief valve and double pressure pipes taking oil to the rear hydraulic control block. The suction-side check valves mount on the rear cover of the gear pump, while the optional double pilot-operated check valve is located on the rear hydraulic control block.

Four standard external gear pumps, for unidirectional or reversible operation, can be used in the UP40. They are part of the Bucher 05 series. They have 4 • 2018

FLUID POWER WORLD

Phone +1 203 245 1100 USA I Switzerland I Germany I China info-us@sfckoenig.com

www.sfckoenig.com

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DESIGN NOTES

displacements ranging from 0.25 to 0.9 cm3/rev (0.015 to 0.055 in.3/rev) and maximum pressure ratings from 200 to 230 bar (2,900 to 3,330 psi). Higher displacements are available, but their power requirements are not matched by the ratings of the electric motors used.

Three standard aluminum tanks have nominal capacities from 0.5 to 1.5 l (30.5 to 91.54 in.3).

The permanent-magnet electric motors currently available come in 12 or 24 Vdc versions (48 Vdc on demand) with power ratings of 0.5 kW (80 mm dia.) or 0.8 kW (85 mm dia.) and in standard protection class IP54. For specific projects, special configurations with other power ratings and/or protection classes can also be considered.

Thanks to its design, this mini power unit is also ideally suited for direct combination of the power unit and a cylinder into a single unit, according to company officials.

As a result, the installation dimensions in machines can be significantly reduced, as there are no extra hydraulic connections. It is also important to note that the UP40 power unit can be installed either horizontally or vertically.

The UP40 mini power unit is particularly suited for areas like hydraulic wheelchair lifts, small tail lifts for trucks, stretchers for special emergency transports, gate openers, capstans, small hand pallet trucks and many other applications where the hydraulic power unit must be extremely compact.

FPW

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4/13/18 10:46 AM

ENERGY EFFICIENCY

Ron Marshall • For the Compressed Air Challenge

Compressed Air Fail: Settings problem causes high unload hours A paint manufacturer had a small compressed air system consisting of four lubricated screw compressors feeding general plant compressed air flows. As part of a compressed air assessment, the compressor operations were monitored and found that all four of the compressors were running during production—but they were at reduced duty cycle. This was easily confirmed by observing the compressor running versus loaded operating hours (see photograph).

A check of the collected data showed that all the compressors were fighting with each other for control. This caused all of the compressors to load and unload, seemingly at random—and although each compressor had automatic shutdown, none of the compressors stopped at any time during production hours.

A calculation showed that, rather than four compressors, only two were required to run during average conditions.

A check of the compressor pressure settings showed that all the compressors were set to exactly the same load and unload set points, rather than the typical cascade scheme. These settings were adjusted and two of the compressors immediately unloaded and shut down.

One of the remaining compressors went to full load, its most efficient point, with the other running in trim duty, taking the remainder of the load. Data logging showed that a savings of 25% was gained just by a push of a few buttons. The power of measurement and observation of a compressed air system was confirmed again.

The comparison of running versus unloaded hours shows this compressor is inefficient, running at only 30% duty.

FPW

Ron Marshall is a compressed air energy efficiency expert at www. compressedairaudit.com. Join the Compressed Air Efficiency discussion group at https://www.linkedin.com/groups/12065406

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4/13/18 9:24 AM

DISTRIBUTOR UPDATE

NAHAD Convention comes to South Florida Paul J. Heney • VP, Editorial Director

O

One of the best fluid power events of the year is coming up, as NAHAD, the Association for Hose and Accessories Distribution, hosts its 34th Annual Meeting and Convention at the JW Marriott Marco Island Resort in southwestern Florida. Located about an hour south of Fort Meyers, Marco Island is a popular winter destination and many outdoor activities abound, from the beaches to the golf course.

More than 900 industry professionals are expected at this year’s event, scheduled for April 28 to May 1, and the host hotel has already sold out. The event, which was held in San Antonio in 2017 and Colorado Springs in 2016, has seen impressive growth.

NAHAD always brings a great spectrum of speakers to their events, but the Convention also boasts a series of hospitality events on Sunday evening that are fantastic networking opportunities. The popular Showcase of Hose Solutions, which will be held on Monday evening and Tuesday morning, is a must-visit exhibit hall with 164 different distributors and associates showing off their products and services for the many distributors in attendance.

Scheduled speakers include:

• Alan Beaulieu—Economic Update: A Good Year Ahead • Jonathan Taplin—Is Amazon an Existential Threat to Your Business?

• Judy Hoberman—Women in Leadership • Herb Meyer—What in the World is Going On? • David Nour—Innovate & Collaborate

In addition to the plenary programs, there are many breakout opportunities for distributor attendees to further their education and careers. Saturday includes a speed networking session and a first-time attendee event—as well as an emerging leaders special session.

Sunday features a happy hour for the emerging leaders and first timers. And breakouts with David Nour on Monday cover topics like Co-Create—How to Think & Lead Differently About the Evolution of Your Business and Implementing Co-Creation—Why Delivering Creative Value is More Complex than You May Think FPW

To register, visit the all-new NAHAD website at nahad.org.

Attendee and spousal/guest programs are optional and include a shelling and sailing eco-tour, brunch, pool and beach networking, an Everglades excursion, 10,000 Islands wave runner excursion, a golf tournament, tennis, and a botanical garden tour/lunch.

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WHAT Connect with thousands of DO engineering YOU design THINK? professionals online.

www.fluidpowerworld.com

4/18/18 10:16 AM

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FUNDAMENTALS

Josh Cosford • Contributing Editor

What is a Beta Ratio, and why should you care?

Beta Ratio refers to the efficiency in which a given filter element removes particles of a given size. The Beta Ratio is calculated using the ISO multi-pass test standard 16889:1999. The test involves adding particles of a known size to the test fluid until the fluid reaches a saturation point, and then bringing the filter online to remove particles in one pass through the element.

The testing equipment uses particle contamination measuring equipment to test the hydraulic fluid before—and then after—the filter element to compare the particles that existed upstream of the element to the particles remaining downstream of the element. The quotient of the number of particles of a given size is the beta ratio.

It’s important to consider a Beta Ratio is only valid for a given particle size.

For example, if a filter element is rated for 5 micron (also written as 5 µm), the Beta Ratio applies to that size particle alone. The Beta Ratio itself is calculated by dividing the number of upstream particles by downstream particles. For example, if 100,000 5-micron particles were measured, on average, before the filter, and 100 5-micron particles were measured after the filter, the beta ratio was 1,000.

For a filter element particle rating to be valid, the manufacturer absolutely must advertise the Beta Ratio observed for that level of filtration. Even poorquality filters can trap some level of 5-micron particles, but the Beta Ratio will be in the 2-10 range, which is not acceptable. Most experts agree a Beta Ratio for a given particle size should be at least 75 to achieve a reasonable level of effectiveness. High quality, efficient filter assemblies can achieve 200 to 2000 Beta Ratio for a given particle size, and I would recommend you should use as high-quality filtration as is reasonable.

When a Beta Ratio is measured, it provides you with the efficiency rating of the filter element at its given particle size. The efficiency is calculated by subtracting 1 from the beta ratio, and then dividing by the Beta Ratio. For example, ß₃ >200 rating is (200-1)/200 = 0.995, or 99.5% efficient at removing 3-micron particles. The Beta Ratio of a filter can change as it collects particles, and most often times, the filter becomes more efficient. However, the increase in particle load also increases backpressure, so it’s important to consider Beta Ratio only for new filter elements.

Beta Ratio provides an industry standard to allow us to make intelligent choices in the care of our hydraulic systems. All reputable filtration manufacturers proudly display their Beta Ratios as a sign of care and quality. Use only high Beta Ratio filter elements in your hydraulic system to ensure long life and proper operation.

Hydraulic filter elements are rated by the efficiency in which they remove particles of a given size.

This is called Beta Ratio. | courtesy of Hy-Pro Filtration

FPW

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4/13/18 8:57 AM

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MAINTENANCE

High-pressure hose must be routed to flex in only one plane.

10 tips for easy hose design and maintenance

Mike P. Beining • Project Manager • Eaton

To correctly route and properly install fluid conveying components during a machine prototyping, follow these 10 general rules. These guidelines are most useful during machine prototyping. Normal production procedures should be followed after all “bugs” have been removed.

1

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Start with large lines — Install the largest ID lines first as they are the hardest to bend and maneuver, especially in tight spaces. Then, the toughest part of the job is done. Smaller lines provide more routing versatility and can be more easily worked in tight spaces, so route each line to conserve maximum space. This not only results in a neater-looking installation, but makes future modifications or additions of accessories easier, more convenient and more economical.

4 • 2018

www.fluidpowerworld.com

4/13/18 2:43 PM

Good installation techniques are essential to efficient operation and obtaining the maximum life of a hydraulic system. However, hydraulic hose and tubing are fatigue items with a finite service life.

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Correct hose length — The appearance and efficient operation of a system often depends on using proper length hoses. Excessive hose footage increases pressure drops and system cost. Hose assemblies are commonly manufactured to specified lengths as well as increments of lengths to minimize the size of the inventory, which must be carried.

When computing hose length, remember that hose can elongate as much as 2% or contract as much as 4%.

Hose flexing — A hose assembly is designed to flex or bend, not twist. In fact, if a large-diameter, high-pressure hose is twisted 7°, its service life can be significantly reduced, in some cases by as much as 90%. High-

pressure hose must be routed to flex in only one plane. If plumbing requires that hose be routed through a compound bend, the hose should be “broken” into two or more sections so each will flex through only one plane. A spring guard will keep hose from bending beyond the minimum bend radius at the fitting, but it will not prevent the hose from twisting.

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Pivot points — When hose must flex, route it through the pivot point around which the component is moving. This will result in the best and most efficient flexing of the hose line, use the least amount of hose and keep the hose within the contour of the machine. To achieve this, the hose should be positioned to bend like a hinge. Otherwise, the hose may have

To avoid abrasion as much as possible, properly route and clamp the hose or use a protective cover.

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a tendency to take an S-bend, which is most likely to happen when

the hose is pushed rather than bent. An S-bend installation results in

excessive hose movement and reduced service life. When piping a

flexible line through a pivot point, consider the relative positioning

of the two end fittings to avoid an S-bend by following this procedure: Swing the moving component to its farthest point where

the hose will experience its widest bend. If the fittings are placed in

parallel planes at this point, the hose will tend to flex in a hinge-like

manner when the component is swung back to the opposite end of

its travel.

Reciprocating motion — In addition to flexing, the ends of the hose may have to reciprocate. There are several design methods to do this:

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A piping installation is not complete until it has been properly clamped.

• Hose reels — For use with high-pressure hydraulic hose, these reels are equipped with high-pressure swivel joints and a spring return to help rewind the hose.

• Festooning — Hose is hung in loops from a steel cable. As one point of the loop moves away from the other, the loops open to form an almost straight line.

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IF YOU USE HYDRAULIC FLUIDS • Rolling — Hose is arranged in an unbalanced U-shape

with hinged tracks carrying the hose. One leg is left

stationary and longer than the second, which is free to

reciprocate parallel to the first.

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Rotary motion — Swivel or rotary joints are commonly used to provide rotating motion. Where rotary movement is a continuous 360°, use a rotary joint. If movement is reversing, a swivel joint would be the better choice. When used with hose, a swivel joint will avoid hose twisting or bending at the fitting.

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Control oil spray — Fire protection must be used where hydraulic lines are routed near hot, potentially hazardous areas. This prevents oil from a broken line from spraying onto any potential source of ignition. There are several ways to accomplish this:

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sleeve so the oil will flow out of the ends in case of

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• Use fire sleeves either to fit over the hose or built into the hose cover

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To achieve proper hose flexing, the hose should be positioned to bend like a hinge.

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Avoid abrasion — Most hydraulic hose is built with a tough outer cover to protect the hose reinforcement from abrasion or moisture damage. However, constant abrasion at one point will eventually puncture the outer cover and weaken the rein- forcement. This is the number one cause of hydraulic hose failures in the field. To avoid abrasion as much as possible, properly route and clamp the hose or use a protective cover.

Choose from a variety of protective coverings:

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Minimum bend radii — The hose must be routed to accommodate the minimum bend radii of that hose. Minimum bend radii for various size hoses can be found in SAE specifications and hose manufacturers’ catalogs. These

figures usually refer to the minimum bend radius at maximum operating pressure for a static line. Exceeding the minimum bend radius can result in kinking of the hose and/or most likely, extra stress at the hose or fitting interface. This causes the cover to become more easily cracked or the internal wire reinforcement to fatigue quicker, both of which will reduce service life.

• Coiled springs • Coiled strap steel

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• Spiraled plastic • Nylon sleeves

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— A piping installation is not complete until it 10 Clamping has been properly clamped. Clamp choice is very important,

and often it can be critical to the installation. Common sheet metal clamps will not hold a large, high-pressure hose.

Good clamps can be inexpensive, yet highly effective for high-pressure surge lines. Anticipate and plan for a possible length change ranging from an increase of 2% to a decrease of 4% for high-pressure lines.

Properly sized clamps should grip the hose in a

positive manner. To keep the clamp from abrading the

hose, the ID of the clamp should be about 1⁄32 in. smaller than the OD of the hose.

Good installation techniques are essential to efficient operation and obtaining the maximum life of a hydraulic system. However, hydraulic hose and tubing are fatigue

items with a finite service life. Eventually these wear items will fail. Typically, basic maintenance techniques are not enough to sufficiently prevent failures from occurring,

whether it be visual inspection or time-based preventive schedules.

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H Y D R A U L I C S

O F F S H O R E

Hydraulic hybrid powers fuel-efficient tug Engineers take a novel, low-risk approach to marine propulsion.

Ken Korane • Contributing Editor

Much like the trend in mobile-equipment markets over the last decade, ship builders and their suppliers have made steady, incremental improvements in terms of vessel performance, fuel efficiency and lower emissions. Many in the marine industry are now pushing the next wave of innovation with more-complex but “greener” systems like diesel-electric hybrids and battery-based power plants. Yet, at the same time, owning and operating (O and O) costs are still the key drivers for the customer’s bottom line.

“It’s a bit of a balancing act,” explained Nathan Kelly, Product Development Manager with Caterpillar Marine, headquartered in Hamburg, Germany.

“Many factors relate to cost—everything from upfront price, up-time and fuel efficiency to maintenance costs and, ultimately, the resale value. And in the back of everyone’s mind are safety and regulatory issues like emissions. With change comes risk. We have to make sure that the latest technology being implemented into the market is not only shiny and fancy and new, it actually benefits customers’ O and O cost and it’s done so in a safe and compliant way.”

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Cat Marine’s Advanced Variable Drive powers the propeller driveshaft via the main engine and a hydraulic motor.

As a result, engineers at Cat Marine are taking a novel approach to addressing users’ demands for higher performance and efficiency—while mitigating the

risk. The company recently announced a collaboration with Sanmar Shipyards in Istanbul, Turkey to build an innovative tugboat with a hydraulic hybrid propulsion

system. Called the Cat Marine Advanced Variable Drive (AVD), the patented system reportedly leverages Caterpillar’s extensive know-how in integrated power systems

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initially developed for mining and construction applications. Sanmar, with 40+ years of experience and the largest tug builder in Turkey, is recognized as a market leader at the forefront of the tug building industry.

Hydraulic hybrid propulsion The AVD system provides significant improvements in both fuel efficiency and vessel performance through a hydromechanical propulsion system, said Kelly. Like many tugboats, the Sanmar design has two main engines mounted side-by-side and driving twin propellers. But it also includes two hydraulic motors and an auxiliary engine.

In a conventional tugboat, each diesel engine turns a driveshaft and powers a single output, the propeller. Throttle setting determines engine speed and operating performance. The AVD, in contrast, is a fully integrated propulsion system, according to Kelly. “Each drivetrain has two inputs—a diesel engine and a hydraulic motor—still with one output, the propeller. Combining the two input powers into a single output is the heart of the AVD.”

The engine and hydraulic motor connect to the shaft and propeller via a planetary gear set, and that allows gear ratios to be freely selected to achieve the required output. This lets the AVD operate the engine at its most efficient point independent of propeller speed—while supplementing power hydraulically. The result is excellent vessel response and performance, along with significant fuel cost savings.

Operating modes The hydraulic motor is part of a hydrostatic system where the hydraulic pump runs off either the main engine or a smaller auxiliary engine. And clutch engagement of the drives to the gear set gives users the option of powering the system with either the diesel engine, the hydraulic motor or both—and lets the AVD run in one of three operating modes.

In the first, called the “work” mode, the main diesel engine is on, seamlessly clutched in, and provides power to the planetary gear. At the same time, the engine turns a hydraulic pump which supplies

the hydraulic motor and aids in driving the planetary gear. This is a parallel-path propulsion system with both the engine and hydraulic motor, through the planetary gears, providing power out to the propeller, noted Kelly.

This hydromechanical-propulsion option permits the most efficient combination of engine and hydraulic system operations, and can accommodate most working maneuvers. “The benefit in doing this is you can optimize your engine speed to whatever is the most optimal efficiency. So you can run your engine as needed, and then you power the planetary gear with the engine as well as the hydraulic motor,” he said.

In the second mode, called the “transit” mode, the main engines are shut off and unclutched, and the auxiliary engine powers the hydraulic motors for both shafts. The hydraulic system provides adequate propulsion for most low-level maneuvers, and running just a single, smaller engine reduces emissions, lowers maintenance costs, and allows for greater operational efficiency.

“This enables you to do any transit or lower load operation for the vessel which, on a tug, we estimate is a very large percentage of its operating time, upwards of 80%. So for 80% of the operating time of the tug, you could satisfy that need with a single, smaller auxiliary engine,” said Kelly.

The third mode, called “boost” mode, involves running both the main engines and the auxiliary engine. This provides full power from the main diesel engines, and supplemental power from the hydraulic motors via the auxiliary engine. This is used for bollard pull (the zero-speed pulling capability of a tug), maximum vessel speed and other highpower demands.

“The hydraulic motor is part of a hydrostatic system where the hydraulic pump runs off either the main engine or a smaller auxiliary engine.”

AVD benefits “The AVD is a very versatile product,” added Kelly. It enables a lot of the performance enhancements that are necessary to improve fuel efficiency, emissions, smoke and noise, as well as vessel maneuverability and response—all the things

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that customers care about when they’re thinking about new technology.

And for customers hesitant to embrace cutting-edge technology due to the inherent risk, the AVD is a well-tested system that has been used on Caterpillar mining equipment for about five years. “We have a good reference point in terms of the actual efficiency benefits that it provides,” along with the underlying design and development process and overall track record in the field, he said. “The AVD system is a proven technology that we’re now implementing into marine applications to satisfy customer innovation demands. There’s a lot of interest in hybrid systems and batteries and electric-drive systems. This is a bit of a different approach to that same problem.”

As mentioned previously, the AVD allows propeller speed independent of engine speed to optimize engine efficiency, leading to fuel savings of 15 to 20%. Basically, it offers all the benefits of a variable-speed

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diesel-electric propulsion (DEP) system with a much smaller footprint and price, said Kelly. Many larger offshore vessels have moved to electric systems for the inherent efficiency benefits. “But those systems are very large and expensive. The AVD accomplishes the same goal, and it’s smaller and lower cost than a DEP system. Hydraulic motors are a fraction of the cost and size of electric motors, and the hydrostatic circuit is much more economical than the power electronics needed for an electric system,” he emphasized.

Main engines can be downsized in most applications with supplemental power provided by the auxiliary engine. For example, the Sanmar AVD system will use Cat 3512 engines. A conventional tug with the same capabilities would require Cat 3516size engines, which measure about 2.5 ft longer and with displacements about 20% higher.

For the same total installed power, the AVD system enables a more efficient installation with smaller main engines, and an auxiliary engine that would see moreoptimal use. Plus, the secondary engine doubles as a firefighting-pump engine, which adds to the versatility of the system, said Kelly. In contrast, many conventional vessels require a dedicated firefightingpump engine that is generally underutilized.

The AVD system is also flexible and can accommodate either diesel, natural gas or gas-turbine engines as prime movers, to provide various levels of engine load capabilities and speeds. And because auxiliary engines can accommodate low load or transit operations, that greatly extends the time between overhauls and reduces service costs on main engines. Finally, the system provides inherently high levels of propulsion redundancy.

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A look at subsystems The Sanmar tug’s two Cat 3512 main engines are sizable, V-12, 58-liter units that measure about 8.5 ft long with 7-ft height and width. Each generates about 2,000 hp. The single auxiliary engine is a Cat C32.

While smaller than the main engines, it’s

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The Cat AVD on the Sanmar tugboat has two main engines mounted side-by-side.

still a large V-12 with a 32-liter displacement generating about 1,500 hp.

The variable displacement, axialpiston pumps and motors that make up the hydrostatic drive system are designs proven from years of experience in construction and mining applications. They’re quiet, efficient and, in this application, run at low to medium pressures.

However, the overall power requirements are significantly greater. “A 70-ton bollard pull tugboat is on a much larger magnitude of power than on some of the mining equipment. So the size and design of the system is new and, in addition, there are two propulsion systems with two propeller shafts. But the actual technology behind the AVD concept is unchanged,” he said.

Kelly hesitated to specify the exact sizes of the hydraulic components, stating “It’s a very scalable solution.” Previously when a design required a certain bollard

pull, engineers weighed various engine options from the different manufacturers in order to precisely size them to the application, he explained. Now, designers can specify a smaller main engine and then scale the hydrostatic system as needed to meet maximum power requirements. For this specific system, the hydraulic power is approximately 500 kW (670 hp) per shaft. But the hydrostatic output can be easily scaled up or down as needed to meet requirements of a wide range of vessel types, applications, and power levels, he said.

Bridge controls will include a pushbutton display for selecting the operating mode. In addition, a firefighting-pump option provides propulsion via the main engines, similar to the work mode, while the auxiliary engine powers the firefighting pump. The entire AVD system of engines, thrusters, gearboxes, pumps, motors, electronic controllers and bridge controls are part of a Cat-branded package and serviced through Caterpillar’s dealer network.

Sanmar specifics The Sanmar hydraulic-hybrid under construction is a RAmparts 2400SX harbor tug designed by Robert Allan Ltd., rated for

70-ton metric bollard pull and carrying a FiFi 1 firefighting designation. (Such a system can spray about 10,500 gpm of water more than the length of a football field.)

In addition to improved performance, lower noise and lower emissions, some of the real benefits of the AVD are the size and the cost, compared to a conventional electric batterypowered hybrid system. Thus, Cat Marine has initially targeted tugs, which have small, compact engine rooms. In addition, the harbor tug operating profile makes the AVD a good fit, said Kelly. Compared to a conventional tug with equivalent bollard pull, the return on investment (ROI) is estimated at three years or less based on projected fuel and operating cost savings.

However, because it’s scalable, the system could easily be integrated into larger or smaller vessels in the future, he said. “From a strategic standpoint, we’re really looking at the AVD system as an alternative to some of the other hybrid solutions, like battery-powered hybrid systems. On the other hand, the benefits in terms of O and O cost and efficiency increase when you get to very high load profiles and more cyclical operations. So we feel like there are other applications, dredge for example, with high load factors and different cyclical operations, that could really benefit from this system as well.”

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Going soft

on grippers There’s a growing interest in nontraditional pneumatic end effectors that offer flexibility and a deft touch.

Ken Korane • Contributing Editor

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P N E U M A T I C S

Pneumatic grippers have been used for decades to pick up, carry and place everything from tiny electronic components to sizeable objects like engine blocks and lumber.

Most have rigid fingers or jaws, usually made of steel or aluminum.

Such devices work well in highly repetitive industrial and manufacturing operations, often with great precision. But they’re not so adept at less structured tasks, such as grasping products that are delicate or vary in size and shape. As a result, many operations still rely on manual assembly and handling.

That world is changing. Robotics technology is rapidly advancing with developments like soft robots and cobots—versatile machines that can work side-by-side with people in food harvesting, medical assistance, warehousing and other non-traditional settings.

Likewise, there is a growing demand for new types of robotic end effectors, such as soft grippers, to aid in the automation push.

Soft grippers, unlike conventional mechanical devices, are made of compliant materials and are frequently powered by compressed air. Interest is on the rise with the growing demand for more-versatile devices that can interact in less-structured environments. For example, automated harvesting and packaging of fruits and vegetables

Festo’s OctopusGripper is modeled on an octopus tentacle and has a pneumatically controlled soft silicone structure.

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requires grippers that can handle delicate products that would be easily damaged by typical hard grippers. Likewise, e-commerce warehouses need grippers that can manipulate packages of various sizes, shapes and weights.

Soft grippers offer numerous benefits over their more-rigid counterparts. Thanks to the inherent cushioning of pneumatics they can conform to surfaces or objects, absorb energy to maintain stability, exhibit physical robustness and human-safe operation at potentially low cost. Internal pressure resists buckling and distributes stresses throughout the structure.

Porting compressed air in and out of the system controls motion.

With few parts, they eliminate bearings, shafts and other mechanisms. The devices typically weigh less and can be safer than traditional end-effectors because they minimize impact forces in the event of a collision. The downside, important in some applications, is that they sacrifice accuracy for compliance.

Soft grippers open the door to the handling of products that heretofore were difficult or impossible to automate. As a result, they may relieve human workers from many monotonous or dangerous tasks. Researchers at universities and R&D labs across the globe are pushing the envelope of soft gripper technology. Here’s a closer look at some new innovations, as well as a few tried-and-true designs.

Firestone AirPicker and AirGripper devices have a rugged, fabric-reinforced rubber construction. Their flexible inflatable shape lets them attach to fragile or sensitive items of varying dimensions and hold them gently and securely in place.

Soft Robotics Soft Robotics Inc., a Harvard University spin-off formed six years ago, has developed a number of pneumatic grippers that largely focus on food handling, packaging and industrial ap48

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plications. According to company officials, a major limitation in the adoption of robot manipulation systems is lack of access to flexible gripping mechanisms that allow not only pick up but also dexterous manipulation of everyday objects.

They’re attacking that problem by designing and building a system consisting of soft robotic grippers, as well as a control system and software that lets a single engineered device manipulate items of varying size, shape and weight.

The result, they say, is a fundamentally new class of robotic grippers that are adaptive, plug and play, repeatable and reliable.

What is also notable is that the grippers are designed to mount directly on many existing commercial robots.

They’re suited for warehouse logistics involving unpredictable-size objects; advanced assembly tasks that currently require significant labor; and food handling, where sanitation and delicate manipulation are important. In essence, Soft Robotics soft grippers are designed to excel where conventional robotic technology falls short.

The end effectors reportedly let packaging, food and beverage, and industrial robots adaptively handle varying objects with a single easy-to-use device, eliminating the need for tool changes and complex vision requirements. Its high-speed (>3 Hz) controller with millisecond response ensures repeatable and reliable actions. Compatible with every commercial robot controller on the market, the Soft Robotics control unit provides turnkey integration, enabling users to quickly install and commission the system for new or retrofit applications with no additional components or control hardware.

The control unit runs on 24 Vdc and 0.5 A power. Digital I/O includes four 24-Vdc inputs and two 10-mA outputs. The software lets users control all grip parameters including force, actuator spacing and opening width. And the controller can store up to eight setting profiles (grip and release). The unit is rated IP65, and it requires 85 to 100 psi compressed and 2 to 8 scfm filtered and treated air.

The grippers themselves are made of a soft elastomeric polymer material and come

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Pneumatically operated expansion grippers from FIPA gently grip the inner contours of workpieces, providing an effective alternative to suction cups and mechanical grippers.

in a range of designs. For example, fouractuator (four finger) circular food-safe grippers are designed for sorting and packaging applications involving delicate produce and bakery items, like apples or small chocolates.

The unit has a mass of 964 gm and measures 160 mm high. It typically can grasp objects with ODs from 40 to 95 mm, with an opposing finger gap of 63.5 mm.

Cycle time is 88 msec to close and 166 msec to open, and grip force is 2.5 lb per finger. Operating pressure is 0 to 12 psi and temperature range is -10° to 65°C. Air is supplied via 10 mm diameter, push-to-connect, polyurethane or nylon tubing. The device

meets the requirements of FDA-CFR Title 21 for food-contact materials and is rated IP67 protection class.

A similar rectangular version handles products like ears of corn, breadsticks, pastries and stand-up pouches. A fiveactuator circular food-safe configuration is suited for objects of varying weight, shape and size like dough balls and hamburger patties.

On the industrial side, the company’s two-actuator automation gripper is a compact and lightweight configuration for bin picking and other applications involving closely grouped objects like pens, small cosmetics and small plastics. The rectan-

gular tool has an opposing finger gap of 15 mm with a typical grasp range of 1 to 40 mm.

Grip cycle time is 124 msec to close and 234 msec to open, again with a finger grip force of 2.5 lb. It is rated IP52 protection class and has a mass of 337 gm.

Larger six-actuator rectangular units are built to handle more substantial objects like large bags, bread loaves, toys and stuffed animals, large pouches and IV bags. Differing actuator lengths are available on the various tools, depending on the application.

A bionic approach Festo is pioneering soft grippers for use on lightweight robots that are suitable for

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working along with humans. The work stems from the company’s Bionic Learning Network, where engineers develop nature-inspired technologies for industrial automation in collaboration with leading universities and research institutes. Bionically inspired robots with pneumatic drives are well-suited for collaborative working spaces, according to the company, and could represent a cost-efficient alternative to classic robot concepts.

One such soft bionic gripper, called the OctopusGripper, was introduced at last year’s Hannover Fair in Germany. The device is modeled on an octopus tentacle and consists of a soft silicone structure that features pneumatically controlled kinematics with vacuum-based holding force. Applying compressed air bends the tentacle inwards, letting it wrap around and grip an object in a form-fitting and gentle manner. Two rows 17-1864_Kaw_Horz_9x5.25.pdf

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of actively and passively controlled suction cups on the inner surface securely attach to and hold a variety of different shaped objects.

Its soft, inherently flexible structure has great potential for use in collaborative, human-safe working spaces in the future, according to Festo. The flexible gripper is used in combination with the company’s BionicMotionRobot and BionicCobot. These pneumatic lightweight robots feature natural movement dynamics modelled on the human arm and elephant trunk.

Another interesting development is Festo’s FlexShapeGripper, a device reportedly modelled on a chameleon’s tongue.

The gripper consists of a nontraditional, double-acting cylinder with one chamber filled with compressed air; and a second one permanently filled with water and includes an elastic silicone molding. The

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volumes of the two chambers are designed to compensate for deformation of the silicone part.

The piston, which separates the two chambers, is fastened with a thin rod on the inside of the silicone cap. In use, a robot or handling system guides the gripper so the silicone cap contacts the object. This vents the top pressurized chamber; the piston moves upwards by means of a spring support; and the water-filled silicone part pulls itself inwards. Further movement lets the silicone cap wrap itself around the object, resulting in a tight form fit. The elastic silicone construction precisely adapts to a wide range of geometries. The material’s high static friction generates a strong holding force.

The concept has potential to enable various tasks in the factory. For instance, it flexibly grips a wide range of objects, holds

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Soft grippers and hard knocks

Despite best efforts and novel designs, not all forays into soft grippers are commercially successful—as is the case of Empire Robotics.

Most soft grippers rely on some sort of clamping to secure an object. Empire, in contrast, used “jamming” action with its Versaball grippers, which were designed to fit onto existing robot platforms.

The underlying technology is intriguing. The company developed flexible end-effectors based on the jamming phase transition of granular materials. The device consisted of an elastomeric ball filled with a sand-like material. Supplying pressurized air into the ball caused it to soften.

Then a robot arm forced it against an object, and venting the air caused the granular material to harden and firmly grip the object. Advantages were said to be inherent flexibility, soft contact and a secure grip on complex parts.

The company sought seed capital from investment funds, won numerous business plan competitions, exhibited at major trade shows and reportedly generated more than a half-million dollars in product sales. It even appeared on The Tonight Show. Unfortunately, commercialization fell short, and Empire Robotics closed up shop last year.

parts in place without consuming energy, and it can pick up and release several objects in a single gripping process.

Proven design Not all soft grippers represent cutting-edge and futuristic innovations. Firestone Industrial Products, a unit of Bridgestone, has offered its AirPicker and AirGripper devices for a number of years. These well-proven designs are based on the rugged, fabricreinforced rubber construction used on its bellows-type industrial air springs and flexible actuators.

The handling units, due to their flexible inflatable rubber shape, can attach themselves to fragile or sensitive items of varying dimensions and hold them gently and securely in place. Typical applications

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include handling test tubes, bottles, and cylinders, and are used in assembly, loading, conveying and other manufacturing operations.

The AirPicker end effector inserts into a product while deflated, and then pneumatically inflates outwardly to establish an inner seal and hold the product’s interior walls—letting it be picked up and moved mechanically. The AirGripper collars around a product, then the sleeve inflates inwardly to form a grip around the product’s exterior.

According to the company, the devices are suitable for objects varying in shape or size and offer a wide range of advantages over traditional pick-and-place devices. By simply controlling the pressure within the bladder, they can handle delicate objects securely but with a soft touch. The products

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Flexible Versaball end-effectors worked based on jamming action.

are suited to a wide range of diameters and work piece weights—offering a low cost, durable solution for robotics or mechanical handling systems.

Among the reported advantages, the inflatable rubber construction allows a multiple number of shapes and sizes to be handled with one model. The AirPicker diameter can nearly double over its deflated diameter, while an AirGripper can grip around an object that is only 40% of the deflated diameter. Controlling the pressure in the bladder controls the force on the object, and holding force is distributed over a greater surface area than in a mechanical gripper, resulting in a soft and secure gripping and higher load-carrying capacity.

Rigid mechanical grippers, in contrast, only contact a small area with their fingers. The

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Firestone products also offer non-marring contact, important with glass and plastic objects. And because the units need no seals or bearings, they are more durable than mechanical grippers in dusty environments.

Standard AirPickers can handle objects with IDs from about 0.3 to over 4.0 in.

Standard AirGrippers are for objects ranging from 0.2 to 1.8 in. OD. They come in Neoprene and high-temperature silicone constructions, with respective working temperatures from 0° to 165°F (-18° to 74°C) and -22° to 320°F (-30° to 160°C). They typically run on compressed air at pressures to about 70 psi, although models are available with various inflation pressures to handle light to heavy loads. Depending on the size and application, the devices can carry loads well over 50 lb.

The FlexShapeGripper has a silicone cap that wraps around an object.

The Quality Choice Look to Dura-Bar to perform better than castings and many lowmedium carbon steels for hundreds of applications. Industries using Dura-Bar for their parts include machine tool, fluid power, oil and gas, industrial, defense, mining, agriculture, automotive and more.

Dura-Bar’s dense grain structure, lack of porosity and shrinkage make for a highly consistent materials with superior machinability, thereby reducing production costs. With continuously cast Dura-Bar, no costly patterns are necessary and bars are available as quickly as the next day from an extensive network of distributors throughout North America and in China.

There are many ways to save with Dura-Bar Continuous Cast Iron.

Customers who have made the switch profit most from significant total part cost reduction due to: • Faster Machining Speeds & Feeds • Zero Defect Guarantee • 10% Lighter Weight • Superior Vibration Damping • Pressure Rated to 6,500 psi Contact us to discuss your application at sales@dura-bar.com 800-BAR-MILL (227-6455) or visit www.dura-bar.com

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Compact ID grippers Single-acting, pneumatically operated expansion grippers from FIPA gently grip the inner contours of workpieces without leaving any marks, providing an effective alternative to suction cups and sprue grippers for products with holes or recesses, and for hollow extruded and drawn parts.

They are designed to handle lightweight parts and are suitable for integration into other gripper systems. Smaller versions are for diameters from 3 to 10 mm and feature polyamide gripper heads suited for gripping within small recesses and are FDA-approved for direct contact with food.

Larger versions handle an 8 to 85 mm diameter range. They feature high-strength elastomer bellows made of EPDM or silicone, the latter of which is FDA approved for direct contact with food. Temperature working range for EPDM and silicone bellows are up to 130°C (266°F) and 200°C (392°F), respectively.

They expand via pneumatically driven pistons, rather than inflation, to avoid any risk of bursting.

Optional sensors can monitor piston position.

The grippers accommodate workpieces with varying sizes and weights exceeding 1 kg. And in combination with an extensive range of mounting elements, they can handle products in almost any orientation. Optimal feed pressure ranges from 6 to 8 bar, although feed pressure and holding force can be adjusted to suit individual workpieces.

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P.O. Box 9070 • Fort Wayne, IN 46899 USA

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Overlooking these common causes of hydraulic system contamination could mean catastrophic machine failure. Vigilance is key for maintaining a clean

Hydraulic system contamination: causes and solutions machine.

Carl Dyke • CD Industrial Group Inc.

I picture several things when I think of a hydraulic system malfunction: • damaged control wiring and connectors • a scored valve spool stuck in place • a pressure valve poppet kept from closing completely.

Why do I picture these things? The challenging faults that have triggered a client’s phone call to come and provide hydraulics maintenance training often include these issues. Damaged wiring is the easier of these problems to track down and solve quickly. Harmful particle contaminants are often smaller than what can be seen with the naked eye.

Hydraulic motion control systems—and also hydraulic force control systems (eg. braking systems)—were never meant to circulate a slurry.

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When insoluble particles are mixed with hydraulic fluid, a slurry is the result. Solids within the liquid are a recipe for trouble. Particles whisked along in high velocity flows can be driven in to clearances causing valves to stick. Hydraulic fluid needs to be pure.

When I was a young boy growing up with logging and lumber mill machinery in the 1970s it wasn’t uncommon to drain the hydraulic oil into a bucket during a hose repair, then pour it right back into the tank once the job was completed. These machines were crude and inefficient with simple gear pumps and direct, lever-operated spool valves.

I’m not saying that hydraulic system performance didn’t degrade as grit and sawdust made multiple rounds through

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Seal damaged due to cavitation may mean internal leakage as well as intermittent faults.

the system, but there were no intermittent or catastrophic failures.

It was not a great repair process or maintenance culture, but the cost did not have a great impact on the business at the time.

Today’s hydraulic systems feature tiny pilot circuits with electronically controlled pressure valves. These pressure-reducing valves produce the precise hydraulic force needed to move a proportional directional valve spool to the desired flow opening. The pilot valves that produce this precise pressure in some cases move less than 1 mm (approx. 3⁄64 in.). The internal parts have close tolerances and are small—often they are on the scale of parts found in a ballpoint pen or a wristwatch. The forces produced by these variable current solenoids are low. These are also valves used as the first layer of hydraulic control in very large construction excavators and mining

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Most hydraulic system contamination cannot be seen ... but that doesn’t mean it can’t cause catastrophic failure. Many particles such as the 30 micron, green mineral particle shown, can’t be seen without a microscope. shovels, or for the steering on a grader. A particle of the right size and shape can jam a pilot valve and render an entire machine inoperable for an extended period of time. Additionally, valves used for safety functions can fail when particles are present. Particles from rust, environmental dust as well as slivers of wear metals need to be removed from the fluid if the system is expected to perform reliably.

How does contamination get into a system?

Common contamination ingression paths include the following: • When filling with new fluid • Quick couplers • Through the breather • Cylinder rod scratches • Bad top-of-tank gaskets • Exposed ports during repair • Worn seals • Brand new hydraulic fluid

How do these contaminants get inside? There are numerous ingression paths. Some of these particles are even manufactured on the inside of a hydraulic system. Water is a common liquid contaminant that assists in the creation of extremely hard, iron oxide particles right where a rust patch forms inside a valve.

Sometimes a jug/drum/tote with new fluid is already contaminated. This is either because the bottling or filling plant itself was dirty, the container it has been stored in was dirty, or because the container has been contaminated by multiple careless openings and closings.

A careless filling procedure without proper filtration and cleaning will drag contaminants into the system along with the new oil.

The old practice of using an open pail and funnel to fill a hydraulic reservoir should remain in the past if reliable performance is the goal. Much better methods for filling are available that use a filter-transfer pump to draw fluid from a barrel or tote and pump it directly into the reservoir through a coupler on the side of the tank.

Older style breather/filler caps have very porous mesh (40 microns and larger is typical). They are not up to the task of keeping contamination out. If someone has been shortcutting the filling process by dumping fresh fluid in through the breather port, it becomes an excellent entry point for contamination.

Quick couplers are found on machines as test points, accessory attachments and tank filling points. If they are not absolutely spotless before a connection is made, contaminants are directly forced into the system.

In my experience the five most common solid particle types found in the fluid of a hydraulic system are: • Metals • Silica • Elastomers • Fibers • Rust

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Metal particles are common Metal particles enter a hydraulic system when wire reinforced hose is cut to length with an abrasive wheel just before crimped fittings are attached. A practice that is growing in popularity and that should be considered a standard is to have all hose assemblies cleaned using a compressed-airdriven cleaning projectile before installation.

Filings from drilling, threading and fabricating a metal hydraulic tank are common. Metal fragments are also created when moving parts come in direct contact with each other. This is common in pumps and valves when the hydraulic oil viscosity is too thin. The outlet port pressure of a gear pump will often drive the hardened gears against the inlet side of the housing, causing scuffing and creating aluminum or steel shavings. Some mobile lift machines with long-stroke cylinders that have cycled past their expected service life may produce metal slivers and filings as the piston scrubs against the inside of the cylinder. This is true where the internal stop tube is of insufficient length.

A pump that suffers from cavitation will also generate metal particles. Excessive restriction to flow on the inlet side of the pump creates vapor cavities which implode near the high pressure outlet. During the implosion, the resulting shock wave damages metal surfaces and tears out small particles. The softer metals inside a pump—such as bronze or aluminum—are most prone to this erosion damage. Harder materials such as steel can also suffer this erosion damage, as happens when a runaway cylinder under negative load creates an extremely low pressure zone on the outlet of a partially open, flow or directional valve. Some researchers have found that the presence of solid particles in hydraulic oil makes it even easier for cavitation bubbles to form.

Metal particles that remain in suspension can cause additional erosion as they strike against valve spool metering notches and valve port edges during the high velocity flow that occurs as a valve is first opening, or just before it closes.

Upon the study of metal particle damage alone and the runaway effects that can occur, one can see how important it is to keep hydraulic fluid clean and the forces of cavitation at bay.

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Prevent plugs from soft fibers Fibers from wood, cardboard, paper, shop towels and rags are commonly found in hydraulic system fluids. Elastomer contaminant particles come from hoses, O-rings and seals when they break down.

While these are softer contaminant types, they can easily plug a control or damping orifice. Tiny silica particles (silicon dioxide) are commonly found in topsoil. Quartz rock sand is silica. Other rock minerals and dust on a concrete floor or roadway also contain silica. These hard, sharp edged particles cause catastrophic valve failures.

Filters are not meant to compensate for poor overall maintenance practices where little attempt is being made to operate a system correctly and keep its surroundings as clean as reasonably possible. If hydraulic fluid analysis reports continuously show excessive particle levels for a given system, it can be helpful to enlist the help of an independent filtration and contamination control expert who can identify the source of the contaminants, help design improved maintenance

practices or select and specify more effective filtration products and systems.

It is inevitable that some contaminants will find their way into a hydraulic system. To achieve reliable hydraulic system performance, it is important to find methods to control contamination build-up, and then follow them consistently, even after the contamination control expert has left the site.

It is easy to overlook periods of overheated system operation and forget that these periods may help to create a sludge within the fluid or cause excessive metal-tometal wear when heat has made the oil too thin. The complete picture of contamination control requires vigilance, collaboration and ownership from all who interact with any hydraulic system. Machine operators are commonly tasked with performing filter changes or replacing worn hydraulic hoses.

Often the training they receive (if any), and the instructions in the maintenance manual

cover only the minimum steps related to the task, without regard for your contamination control strategies. Raising awareness of the consequences of excessive fluid contamination can play a vital role in achieving reliable hydraulic system performance.

While there certainly are technical aspects to understanding and controlling fluid contamination, operational and maintenance practice brings the cultural and human factor to the forefront to make the most important contribution.

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FROM DOWNTIME TO UPTIME IN NO TIME. Every minute of downtime costs you money. Whether your failed cylinder is U.S. or Metric, we can repair it to original specs (or better) faster than anyone else— guaranteed. With full-service locations in Michigan, Alabama, and Georgia, we couple 40+ years experience with the most complete cylinder repair facilities in North America. In addition to a deep inventory of repair parts and off-the-shelf components, each plant also manufactures new and custom cylinders to your exact specs. We are at your service 24 hours a day / 7 days a week.

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Mary C. Gannon • Managing Editor

A half-century of offshore insights

The Offshore Technology Conference marks 50 years, as it returns to Houston April 30 to May 3.

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OTC 2018 returns to Houston’s NRG Park April 30 to May 3 this year, marking its 50th year bringing together engineers, technicians, executives, operators, scientists, and managers involved in offshore drilling, exploration, production, and environmental protection.

The oil and gas industry relies on the high-pressure power density of fluid power technologies to maximize exploration, production and drilling in harsh offshore environments.

As wells are dug deeper and become more difficult to reach, the machines that are used in them must withstand extreme temperatures, pressures, damaging seawater and more.

Hydraulics is up to the task. (continued on page 62)

Energy industry professionals will return to Houston yet again this year for the annual Offshore Technology Conference (OTC).

OTC is the largest oil and gas industry event in the world. The event will have more than 2,300 exhibitors and attendees representing 100 countries.

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Accumulators Inc..................................................... 7111 Aidro Hydraulics & 3D Printing................................ 8243 Alfagomma SpA (Kuriyama)..................................... 3949 Ametek..................................................................... 461 API Heat Transfer..................................................... 2778 ASCO Div., Emerson Electric Co............................... 2261 Ashcroft Inc.............................................................. 608 Bal Seal Engineering Inc........................................... 4615 Balluff Inc................................................................. 3933 Blacoh Fluid Control Inc........................................... 6274 Bonfiglioli USA.......................................................... 12041 Bosch Rexroth Corp................................................. 2805 Brennan Industries................................................... 5504 BVA Hydraulics......................................................... 6308 Castrol Offshore....................................................... 1439 Cat Pumps/Ram Pumps........................................... 4701 CEJN......................................................................... 275 Continental ContiTech.............................................. 4915 Controlled Fluids Inc................................................ 6917 Coremo Ocmea SpA................................................. 4047 Danfoss Power Solutions......................................... 4452 Dinamic Oil............................................................... 3145 Dixon Valve & Coupling Co...................................... 4619 DK Lok...................................................................... 3175 Doering Co............................................................... 9072 Donaldson Co. Inc.................................................... 7204 Douce Hydro SAS France......................................... 2115 Dynex/Rivett Inc....................................................... 601 Eaton Corp............................................................... 4838 Elettrotec SrL............................................................ 8231 Elite Controls............................................................ 4452 Elite Seal Inc............................................................. 9073 Enduro...................................................................... 4167 Evonik Corp.............................................................. 7163 Famic Technologies Inc............................................ 770 Faster........................................................................ 5209 Festo AG & Co. KG.................................................... 3625 Fjero A/S................................................................... 4561 Flaretite.................................................................... 7305 Fluid Components International (FCI)..................... 1354 Fluid Power Technology........................................... 3145 Fluke Corp................................................................ 3176 Fluorten.................................................................... 7224 Freudenberg Sealing Technologies.......................... 1922 Fuchs Lubricants Co................................................. 6923 Gates Corp............................................................... 3875 Global Heat Transfer................................................ 10828 GP:50........................................................................ 4201 H&D Distributors Inc................................................ 7230 Haskel....................................................................... 2209

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HAWE Hydraulik....................................................... 4301 Hetonic..................................................................... 4879 High Pressure Equipment Co................................... 1361 Houghton International........................................... 3418 Hunger Hydraulics CC Ltd........................................ 9034 HYDAC International Corp....................................... 1677 Hydradyne LLC......................................................... 3408 Hydraquip Inc........................................................... 4452 Hydratech Industries................................................ 4561 Hydraulics International Inc..................................... 2005 Hydro Leduc............................................................. 2115 Igus B.V..................................................................... 3625 IMI Precision Engineering........................................ 1439 Ingersoll Rand.......................................................... 5705 Innovative Fluid Power............................................ 8847 Innovative Hydraulics LLC........................................ 6325 John Deere Power Systems...................................... 3775 Klüber Lubrication NA LP......................................... 922 Kocsis Technologies Inc............................................ 5109 Kracht....................................................................... 3071 L&M Radiator Inc..................................................... 3067 The Lee Company.................................................... 2109 Liebherr Components North America..................... 3625 G. W. Lisk Co............................................................. 1567 Magnetek................................................................. 4205 Maxpro..................................................................... 2273 MFP Seals, Div. Martin Fluid Power......................... 2678 Midwest Hose & Specialty Inc................................. 3671 Moog Inc.................................................................. 2511 Motion Industries.................................................... 6626 MSC Software Corp.................................................. 7233 MSO Seals................................................................ 4171 MTS Sensors............................................................. 7245 National Filters Inc................................................... 5326 NBB Controls Inc...................................................... 3615 Norman Filter........................................................... 8856 Noshok Inc............................................................... 2905 NRP-Jones, LLC......................................................... 1509 Oerlikon.................................................................... 12024 OP USA Inc............................................................... 8231 PacSeal Hydraulics Inc.............................................. 4718 Panolin..................................................................... 1422 Parker Hannifin Corp................................................ 3639 Pneumatic and Hydraulic Co. LLC............................ 5074 Rota Engineering Ltd................................................ 1639 Rotor Clip Co............................................................ 10921 Rotork....................................................................... 4626 S. Himmelstein & Co................................................ 4277 SC Hydraulic Engineering Corp................................ 375 Seals Eastern............................................................ 1573 Exhibitor list continued page 62 www.fluidpowerworld.com

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Servi Fluid Power Inc................................................ 7412 Smalley Steel Ring Company................................... 1608 Spir Star Ltd.............................................................. 2101 SPX Flow................................................................... 625 Stainless Adapters.................................................... 5324 Staubli Corp.............................................................. 3009 Stauff Corp............................................................... 8734 Stucchi USA Inc........................................................ 5071 SunSource................................................................ 5818 Swagelok.................................................................. 739 Texas Hydraulics Inc................................................. 12140 Thermal Transfer Corp............................................. 7001 Tranter Inc................................................................ 1505

Trelleborg Sealing Solutions..................................... 3227 Turck Inc................................................................... 6320 Twin Disc Inc............................................................ 5075 Uniflex Hydraulic...................................................... 5613 Utex ......................................................................... 1221 Versa Products Co. Inc............................................. 2670 Wandfluh of America............................................... 4452 West Craft Mfg. Inc.................................................. 7436 Wichita Clutch.......................................................... 4605 Wilkes & McLean Ltd............................................... 7362 Womack Machine Supply Co................................... 4314 WPT Power Corp...................................................... 12126 Young Touchstone.................................................... 7001

(continued from page 60)

This is why nearly 100 fluid power manufacturers can be seen on the exhibit floor (see the complete list on beginning on page 61).

The 2017 edition of the event attracted more than 64,700 attendees from 100 countries and all fields in the offshore energy sector. This year’s event will see more than 2,000 exhibiting companies, and 350 technical presentations, 22 topical breakfast and luncheons, and 11 panel sessions.

Technical sessions are broken up into seven topical categories, including: Celebrating 50 Years of OTC—Programming which reflects on our history, the current state of the industry, and what is on the horizon.

Faster Deployment of New Technologies—Solutions to reduce the development timeline and create project-ready technologies which meet current industry challenges.

Cost Reducing Tools and Techniques—Ways to decrease costs and improve overall value, while maintaining high standards for safety, operability, and reliability.

Integrating to Innovate—How advanced software, nanotechnology, and the digital revolution are integrating disciplines and triggering an historic transformation in the offshore energy sector.

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Meeting Global Demand—Meeting the energy needs of fastgrowing economies, while reducing carbon emissions and carefully considering the impact of digital technology.

Updates on World-Class Projects—The latest on landmark projects that have resulted in breakthrough technologies in a low oil price environment.

Global Participation—Executives from service companies and operators, including IOCs and NOCs, share accomplishments from projects in Canada, Malaysia, the Gulf of Mexico, and the North Sea. In addition, OTC will recognize innovative technologies with the Spotlight on New Technology Award. The program is exclusively for OTC exhibitors and showcases the latest and most advanced technologies that are leading the industry into the future.

FPW

To learn more and to register, visit 2018.otcnet.org.

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The Fluid Power Technology Conference brings together fluid power industry professionals and academics for three full days of pre-conference workshops, in-depth programming including keynote sessions, industry panels, hands-on technology demonstrations, and networking sessions.

Featured Keynotes

Program Topics Planned topics Maintenance and reliability The importance of maintenance and fluids Cooling and temperature control Hose failures – causes and effects

Astrid Mozes, Eaton

Austin Ramirez HUSCO International

Diagnostics Circuit basics Practical hydraulics — part 1 and 2

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MAY 14-16, 2018

Milwaukee School of Engineering’s Kern Center

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Now in its third year, the FPTC—slated for May 14 to 16 at MSOE’s Kern Center—boasts expanded session offerings for design engineers and MRO professionals.

Mary C. Gannon • Managing Editor

The

Fluid Power Technology Conference returns to Milwaukee

The third annual Fluid Power Technology Conference offers an expanded three-day program, with technical presentations geared towards OEM design engineers and after-market professionals in the maintenance, service and repair sectors. The event returns to the Milwaukee School of Engineering’s Kern Center May 14-16.

NEW this year will be two pre-conference workshops presented by the experts at the Milwaukee School of Engineering and the International Fluid Power Society, with full-day sessions titled “Fluid Power Basics 101” and “Advanced Hydraulics Workshop.” See sidebar on page 65 for complete descriptions.

The following two days will be packed with more than 20 technical presentations led by industry experts, including faculty from MSOE; Canada’s preeminent

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fluid power trainer Carl Dyke; Fluid Power World’s own Josh Cosford; and experts from the manufacturers themselves. In addition to keynotes from Austin Ramirez from Husco International and Astrid Mozes from Eaton Corp., attendees will have a chance to hear from women in fluid power, tour MSOE’s labs and facilities, and more.

Register at fluidpowertechconference.com.

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New: Pre-conference workshops New to the FPTC are two full-day workshops from 8 a.m. to 5 p.m. at the Grohmann Tower. Registration is required.

Attendees can choose from the following: Advanced Hydraulics Workshop presented by the International Fluid Power Society’s Tom Blansett — Data gathered from IFPS Hydraulic Specialist Certification tests reveals that failure rates are largely due to a lack of knowledge in two fundamental core competencies.

Those are:

| iStockphoto.com

the function of hydraulic components • Uinnderstanding circuits • Using design considerations to select components for hydraulic systems

Tuesday, May 15

Registration opens at 7 a.m. on Tuesday. This day’s agenda includes: 8:00-9:00 – Optional tours of MSOE’s Grohmann Museum and Fluid Power Institute Lab / Rapid Prototyping Center. See sidebar on page 66 for complete details. Registration is required.

9:30-10:30 — Opening Keynote: What Washington gets right—and wrong—about manufacturing, by Austin Ramirez, Husco International 10:30-11:00 — Exhibition Opening/Networking Break 11:00-11:30 — Breakout 1: Give your cylinder a bath: Hydraulic system cleanliness from the cylinder and beyond, by Tony Casassa, Aggressive Hydraulics 11:00-11:30 — Breakout 2: Hose failures—causes and effects, by Josh Cosford, Fluid Power World, Higginson Equipment, Canadian Fluid Power Association

Without in-depth knowledge of these fundamentals, it is difficult to identify, assist and solve customers’ problems.

Many customers could benefit from newer technologies and designs that would increase efficiency and productivity. This workshop will focus on a few key concepts that will help your sales associates gain more confidence and knowledge when talking to their customers.

Fluid Power Basics Workshop presented by MSOE’s Tom Wanke — This introductory level workshop will cover the benefits and challenges of using fluid power systems for power transmission and motion control. Physical laws that govern how and why fluid power systems function will be discussed. Individual components that comprise a fluid power system; including their design, construction, operational performance and efficiency characteristics will be presented. ISO symbology used for representing individual components will be covered. The workshop will conclude with a brief overview of circuit architectures.

Pre-Conference workshop requires separate registration. Visit www.fluidpowertechconference.com for more details.

11:30-12:00 — Breakout 1: Integrated position sensors for telescopic cylinders, by Cary Mulvany, SIKO Products 11:30-12:00 — Breakout 2: Condition Monitoring; Obstacles And Real World Approaches For Results, by Dan Davis, Parker Hannifin Corp., Quick Coupling Division 12:00-1:00 — Exhibition/Luncheon 1:00-1:30 — Breakout 1: Modern mobile complex machine design; MATCH – “Machine Application Tool Chain” by Eric Ringholm, HYDAC

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Three Tours

C O N F E R E N C E

Optional tours give attendees inside looks at Poclain Hydraulics, MSOE

P R E V I E W

1:00-1:30 — Breakout 2: Delivering Value Beyond Fleet Management, by Chad Repp, HED Inc.

Monday afternoon, attendees can opt into an optional tour at Poclain Hydraulics, where they can see the hydrostatic transmission manufacturer’s North American operations.

Poclain manufactures hydraulic motors, pumps, valves, electronics and power units for a variety of markets, including construction, agriculture, environment, industrial, material handling, and on highway.

1:30-2:00 — Breakout 1: Cylinders can do anything—A review of 10 specialty designs to spark your imagination, by Peter Frymark and Douglas Lacina, Milwaukee Cylinder 2:00-2:30 — Breakout 1: Creating flexible interactive training material with Automation Studio, by Denis Lenoble, Famic

Prior to the opening keynote on Tuesday morning, attendees can opt into tours by MSOE staff of the Fluid Power Institute, Rapid Prototyping Center, and the Grohmann Museum.

2:00-2:30 — Breakout 2: Slip-in logic cartridges in 3D for plant and mobile, by Carl Dyke, CD Industrial Group 2:30-3:00 — Exhibition/Networking Break

Fluid Power Institute—For more than 50 years, FPI

has been a leader in fluid power research and education by providing practical integrated solutions for fluid power components and systems to world renown manufacturers, OEMs, distributors, users and the US DoD by utilizing experienced faculty, staff and students. FPI has three major focus areas: Engineering Services, Tribology Services, and Test and Evaluation Programs. FPI’s campus lab facility has various hydraulic power units and test systems that can readily be configured to run a wide variety of test procedures and protocols.

3:00-3:45 — Breakout 1: Wireless safety, by Jamie Sanderson, HBC-radiomatic

Rapid Prototyping Center—The RPC is an

4:30-5:30 — Exhibition/Networking Reception

3:00-3:45 — Breakout 2: MSOE Presentation — Benefits of filter debris analysis, by Paul Michael 3:45-4:30 — Keynote Presentation: Dynamic machine control: A new era in hydraulics, by Astrid Mozes, Eaton Corp.

industrially-supported laboratory focused on additive manufacturing/3D printing technology. RPC has the resources and 25 years of hands-on experience to apply to any challenges. Whether one needs a functional prototype or insight into new manufacturing processes, the center provides additive manufacturing services, applied research, product/process development support, and educational services for MSOE's 40+ industrial consortium members.

Wednesday, May 16 Wednesday morning begins with registration starting at 7:30 a.m. The agenda includes the following: 8:30-9:30 — Opening Keynote: Women in fluid power panel discussion, featuring Caryes Allan, Higginson Equipment; Céline Cabana, FD Groups America; Dr. Monika Ivantysynova, Maha Fluid Power Research Center at Purdue University; Rachel Schmidt, Elwood Corp.; and Taryn West, K.R. West Co. Moderated by Mary Gannon, Fluid Power World

The Grohmann Museum—The museum is named

for Dr. Eckhart Grohmann, an MSOE Regent, Milwaukee businessman and avid art collector, who donated this collection to MSOE in 2001 and subsequently the funds to purchase, renovate and operate the museum. The Eckhart G. Grohmann Collection “Man at Work” comprises more than 1,000 paintings and sculptures from 1580 to the present.

They reflect a variety of artistic styles and subjects that document the evolution of organized work.

9:30-10:30 — Breakout 1: Hydraulic System Maintenance and Troubleshooting, by Carl Dyke, CD Industrial 9:30-10:30 — Breakout 2: Cleanliness Monitoring and the Advantages of Online / Inline Particle Counters against Bottle sampling analysis, by Geoff Grant, MP Filtri Group 10:30-11:00 — Exhibition/Networking Break 11:00-11:30 — Breakout 1: Modeling & Simulation of a Braking System HPU, by Céline Cabana, fd-groups 66

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11:00-11:30 — Breakout 2: Advanced Hydraulic Motion Control Design Practices, by Jason Palmer, Delta Computer Systems

Astrid Mozes

11:30-12:00 — Breakout 2: Understanding Seals in an Industrial Environment, by John Plut, Freudenberg Sealing Technologies

Keynote presentations find the pulse of industry

12:00-1:00 — Exhibition/Luncheon 1:00-1:45 — Breakout 1: Cab Systems solutions for the OEM,

by GS Global Resources

Attendees won't want to miss three keynote presentations. These high-level talks will shed light on trends in the industry and where the fluid power market is headed.

First up is Husco International’s Austin Ramirez, who will open Tuesday with his presentation, “What Washington gets right—and wrong—about manufacturing.” Ramirez, President and CEO of HUSCO, was selected as a White House Fellow and served on the National Economic Council for both the Obama and Trump Administrations. He will discuss HUSCO’s culture and the company's strategy for success. He will give some general observations on his time in the White House and how he thinks we can fix our political system. Ramirez will explain a policy framework for sustainable success of U.S. manufacturing in an environment of growing populism and a rising China.

Prior to his current role, Ramirez served as President of INCOVA Technologies, a subsidiary of HUSCO, as well as director of strategic business development. He earned an MBA from the Stanford Graduate School of Business as a Goldman Sachs Fellow, and graduated as an Arjay Miller Scholar, awarded to the top 10% of academic performers in the graduating class.

Tuesday will culminate with Eaton Corp.’s Astrid Mozes, VP, Hydraulics Business, Power and Motion Controls' presentation, “ Dynamic Machine Control: A New Era in Hydraulics." She will review the Internet of Things’ impact on fluid power. The rise of the IoT in the mobile and industrial markets has delivered intelligent components and automation in ways not previously thought to be possible. What is the next step in IoT integration? Mozes will cover where we are now and what we can expect to come as we enter a new era of revolutionary dynamic machine control that will yield never seen before productivity levels.

Mozes joined Eaton in 1990. She became president – Hydraulics Business EMEA in Dec 2010. Prior to her current role, she was CTO for hydraulics. She holds a bachelor’s and master’s degree in mechanical engineering from The Royal Institute of Technology in Stockholm, Sweden.

We’ll kick off the day Wednesday with a panel discussion: "Connecting women in fluid power." Throughout the 2017 edition of the FPTC, one theme resounded over and over again — the need to get more women into engineering and, specifically, into fluid power. Join several leading women from different aspects of fluid power as they discuss why this predominantly male industry has been tough to break into and how we can—and should—make changes to the status quo.

Moderated by Fluid Power World’s Managing Editor Mary Gannon, the panel will include educators, executives, distributors and manufacturers. Panelists scheduled to appear include Dr. H.C. Monika Ivantysynova, Maha Professor Fluid Power Systems and Director of the Maha Fluid Power Research Center at Purdue; Rachel Schmidt, Sales Application Engineer with Elwood Fluid Power; Caryes Allan, Vice President, Higginson Equipment; Taryn West, Vice President, K.R. West Company; and Céline Cabana, Technical Account Manager, FD Groups America.

1:00-1:45 — Breakout 2: Hydrostatic Drive Troubleshooting Bootcamp, by Carl Dyke, CD Industrial 1:45-2:30 — Breakout 1: Choosing the right quick connect coupling for your application, by Andrew Wasielewski, CEJN 1:45-2:30 — Breakout 2: Student poster presentations 2:30-3:00 — Student Poster Sessions/Networking Break 3:00-3:45 — Breakout 1: Electrification of mobile hydraulic control systems, by Mark Jankowski, Thomas Magnete 3:00-3:45 — Breakout 2: Tie rod cylinder maintenance— Rebuilding a cylinder, by Peter Frymark and Douglas Lacina, Milwaukee Cylinder 3:45-4:45 — Breakout 1: Circuit basics, by Dr. Medhat Khalil, MSOE 3:45-4:45 — Breakout 2: Tools for Condition Monitoring, by Kate Kerrigan, MSOE

To register and for the latest schedule updates, visit fluidpowertechconference.com.

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C O N F E R E N C E

P R E V I E W

| background image iStockphoto.co

m

Special thanks to all sponsors, including the following:

Host University:

Exhibitors:

Milwaukee School of Engineering

Dura-Bar Elwood Corp. fd-groups HBC-radiomatic Inc. IC-Fluid Power Inc. Nitro Steel a div. of Premier

Thermal Solutions MTS Sensors Webtec

Platinum Sponsor: HYDAC Technology Corp.

Gold Sponsors:

Standard Parts.

Winco.

Hydraulic Components JW Winco’s immense offering of standard parts for controlling, venting and sealing of liquids and gases includes: ■ ■ ■ ■ ■

Oil Level Sight Glasses Oil Level Indicators Threaded Plugs / Sealing Plugs Oil Drain Valves Breather Valves / Filters / Strainers

Explore our full line or contact us with your application requirements.

Aggressive Hydraulics CEJN North America Delta Computer Systems Inc. Grimstad Famic Technologies Inc. Freudenberg Sealing Technologies GS Global Resources Inc. HED Inc. Milwaukee Cylinder MP Filtri OEM Controls Inc. Parker Hannifin Price Engineering Servo-Kinetics SIKO Products Thomas Magnete TTP, an API Heat Transfer Co. VEST Inc. WIKA USA

Corporate Registration Sponsors Systems Inc. – Loading Dock Equipment

Media & Industry Sponsors: Fluid Power World MSOE ESA OEM Off-Highway IFPS Canadian Fluid Power Association

J.W. Winco, Inc. Phone 800-877-8351 Fax 800-472-0670 Email sales@jwwinco.com www.jwwinco.com

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4/18/18 11:03 AM

PRODUCT WORLD

Cloud-based analysis tools Piab piab.com Piab is now introducing piSMART versions of its most advanced vacuum

Leakage Warning systems etc. Similarly, cycle counting features can reveal

technology products. Focused on maximized productivity and energy-efficiency,

if the number of “picks per minute” is dropping over time, potentially

piSMART vacuum equipment places new cloud-based analysis tools in the

indicating performance issues relating to a build-up of dirt or blocked

hands of operators.

filters.

Building on intelligent features already available in some vacuum

Such “big data” analysis procedures will include auto tuning,

equipment, piSMART will offer a new level of control that underpins the pillars

condition monitoring, predictive maintenance, simulations and real-

of Industry 4.0. For the packaging industry this means that large amounts of

time adjustments, based on existing features such as Automatic Level

output data regarding, for instance, vacuum level changes can be collected and

Determination (ALD), Automatic Condition Monitoring (ACM), Intelligent

compared with data easily accessed from the cloud, offering highly intelligent

Blow-Off (IBO), Self-Adhesion Control (SAC) and Energy Saving (ES).

Quiet power take-off Muncie Power Products munciepower.com/quiet The FR6Q—a new quiet power take-off—is designed to fit Ford 6R140 transmissions.

The FR6Q has the latest in noise abatement technology.

With the FR6Q’s patent-pending spring-loaded rocker mechanism, virtually all gear rattle noise is eliminated for a quiet power take-off.

The FR6Q fits 4X2 and 4X4 Ford Super Duty trucks,

F-350 to F-550, with the Ford 6R140 transmission, but may also be used on F-650 and F-750 trucks. The FR6Q has a one-piece installation with rocker. It has up to 200 lb-ft. of torque capability.

The FR6Q boasts a preconfigured wiring harness, is

solenoid activated and available with direct-mount pump drives or round shaft output options. The FR6Q operates in stationary and mobile modes. It is suited for the tow and recovery, dump, utility and snow and ice markets as well as applications such as cranes, compressors and vacuum tanks. www.fluidpowerworld.com

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PRODUCT WORLD

NFPE control option for MP1 pumps Danfoss powersolutions.danfoss.com Danfoss introduces a non-feedback proportional electric (NFPE) control option for its MP1 closed circuit axial piston pumps. The MP1 already provides modular configuration for manufacturers seeking a reliable pump, and the NFPE control expands the MP1 control portfolio for further customization.

The NFPE control will be available in the first quarter of 2018 as a standard option for all

MP1 frame sizes (28/32 and 38/45cm³). The scope of MP1 applications is broadened with the control portfolio that now includes 3-position electric control, electrical displacement control, manual displacement control and the new NFPE control.

Implementing the NFPE control option enables OEMs to use the MP1 pump as an

automotive type control solution, as it combines the innovative MP1 pump portfolio with proven Danfoss controllers and software. It is designed to enhance applications such as compact wheel loaders, dumpers, sweepers and telehandlers.

Custom Hydraulic Cylinders for Offshore

Drill Ship

Hydraulic Ship Crane

Over 70 years experience

See Us At

OTC 2018 April 30 - May 3, Booth #9034 Houston, TX

Drill Platform

Hunger Hydraulics C.C., Ltd. 63 Dixie Highway • Rossford, Ohio 43460 Phone: +1.419.666.4510 Fax: +1.419.666.9834 info@hunger-hydraulics.com

Hydraulic Actuator

Shop Testing

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www.hunger-hydraulics.com • +1.800.248.9232 70

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www.fluidpowerworldonline.com

4/18/18 10:50 AM

Mary Gannon • Managing Editor

COMPONENT FOCUS

What’s the difference between crimping and swaging?

While both methods are used to permanently attach a fitting onto a hose, swaging and crimping are different processes, often used on different types of hoses.

An external swage consists of a ferrule passed through a reducing die, usually split, to bring the ferrule OD down to a predetermined size (for proper coupling retention), then forcing the hose tube down into the stem serrations.

The swaging process is as follows: A hose is inserted into a fitting to a specific depth. Then the hose and fitting are placed into a swaging machine, with proper tooling, to create the desired form. This is usually accomplished by pushing the fitting, while on the hose, into a set of fixed dies with a smaller inside diameter than the fitting outside diameter, thus changing the form of the fitting and permanently attaching it to the hose.

Crimping is the act of forming a metal sleeve or ferrule of the hose fitting with a surrounding series of die segments, usually eight, to compress the hose within the fitting.

Crimping a fitting onto a hose is different in that the dies are not fixed and usually come in segments. The die segments are pushed together radially around the fitting to change the form of the fitting to create a smaller diameter.

The crimping process changes the shape of the entire circumference and length simultaneously. Crimping takes a lot more force to reduce heavy wall ferrules.

The basic difference between the two processes is that the swaging starts at the end closest to the hose and begins reducing the ferrule moving toward the fitting, stopping about ¾ of the way up the ferrule. This creates a bell area and a pocket for the excess hose to flow into. In swaging, a machine pushes a fitting and ferrule through a fixed split die bed to reduce the OD of the ferrule, compressing the hose into the stem serrations, while a crimping machine has any number of segment dies that close around the ferrule or sleeve and reducing it to a predetermined OD.

Pictured is Lillbacka USA’s Finn-Power 120 and 120S crimping machines.

WHAT Connect with thousands of DO engineering YOU design THINK? professionals online.

FPW

www.fluidpowerworld.com

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AD INDEX

Aggressive Hydraulics ................ 20 AMETEK STC ............................... 11 Anchor Fluid Power ...................... 3 AutomationDirect ............. 1, insert Brennan Industries ..................... 17 Canfield Industries ..................... 69 Clippard ...................................... BC DMIC .......................................... 31 Doering Co. ................................ 58 Dunkermotoren ........................... 9 Dura-Bar ..................................... 52 Fabco-Air, Inc. ............................. 19 Flow Ezy Filters ........................... 35 Fluid Line Products ..................... 15 FluiDyne Fluid Power ................. 44 HAWE Hydraulik ........................... 7 Holmbury, Inc. ........................... IBC Hunger Hydraulics ...................... 70 Hy-Pro Filtration ......................... 55 HYDAC Technology Corporation .......................... 23 J.W. Winco, Inc. .......................... 68 Kawasaki Precision Machinery ... 50

Kelly Pneumatics Inc. ................. 49 Kraft Fluid Systems ..................... 34 Lillbacka USA, Inc. ...................... 37 Main Manufacturing Products, Inc. ........................... 8 MP Filtri USA Inc. ....................... 57 Nitro Steel .................................. 13 O+P SrL ....................................... 33 PHD Inc. ...................................... 53 Price Engineering ....................... 40 Prince Manufacturing Co. .......... 26 Rota Engineering Ltd. ................. 43 RYCO Hydraulics ......................... 36 Servo Kinetics ............................. 29 SFC Koenig .................................. 25 SIKO Products ............................. 45 Smalley Steel Ring ........................ 5 Stauff Corporation ..................... 21 Super Swivels ............................... 2 Tompkins Industries ............... IFC,8 Veljan Hydrair ............................. 42 Yates Industries .......................... 59

LEADERSHIP TEAM Co-Founder, VP Sales Mike Emich 508.446.1823 memich@wtwhmedia.com @wtwh_memic Co-Founder, Managing Partner Scott McCafferty 310.279.3844 smccafferty@wtwhmedia.com @SMMcCafferty EVP Marshall Matheson 805.895.3609 mmatheson@wtwhmedia.com @mmatheson

FOLLOW US ON

Follow the whole team on twitter @FluidPowerWorld

fluidpowerworld.com pneumatictips.com mobilehydraulictips.com sealingandcontaminationtips.com hoseassemblytips.com

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www.fluidpowerworld.com

4/17/18 11:15 AM

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