The hinged screw cover con guration of the AttaBox Heartland series enclosures provides the highest level of protection against water intrusion with a NEMA 6P rating. These enclosures feature opaque covers and can be padlocked for added security.
• Constructed of polycarbonate with UV inhibitors
• NEMA ratings 1, 3R, 4, 4X, 6P, and 12
• Variable-depth side-mount capability
AutomationDirect is continually expanding our offering of quality enclosures from the
• Aluminum back panel and swing-out panel mounting options
• Thick, robust sidewall construction eliminates sidewall flexing
• Fully non-metallic hinge, does not penetrate inside enclosure
Mary C. Gannon • Editor-in-Chief
Where are we in the tariffs tug-of-war?
IT FEELS LIKE WE’VE BEEN talking about tariffs for months now, with the constant, will they or won’t they take effect? Josh Cosford penned an opinion piece a few weeks ago on this very topic, sharing his thoughts from north of our border as we waited for impending tariffs.
Since he wrote that, some tariffs have gone into effect. But just how is the U.S. fluid power industry handling this sudden increase on materials they need or on the components they sell? Like the tug-of-war uncertainty, the answer seems to also be a waffling “it depends.”
Last year, economists studying the fluid power market indicated we were coming out of our 2024 recession and things would stabilize and grow. But tariffs have disrupted the market and we’re in a very much wait-andsee mode.
In a recent survey of members, the National Fluid Power Association asked how much impact the tariffs were having on their business. Interestingly enough, the biggest impact came in the mobile hydraulics market, said Pete Alles, VP of Member Services and Operations for the NFPA. Anecdotally, I have also found this true in my conversations with fluid power manufacturers. Those whose business are more in the industrial space — whether it’s oil and gas or industrial automation and manufacturing —have said that
tariffs have not caused as much concern for them as others.
When you speak with fluid power manufacturers and distributors to learn if they are increasing prices or passing the cost of tariffs onto their customers, the answer is again, often, "it depends." Distributors seem to be feeling the pressure less than manufacturers, according to the NFPA’s survey, with manufacturers and suppliers being almost even in reporting a negative impact.
I’ve spoken with companies and received emails about their reaction to the tariffs. Some are not making any price increases currently. Those that are passing the tariff costs on, usually are putting a line-item fee on their invoices.
While we expect Chinese imports to take a big hit, what fluid power manufacturers have indicated is that there is greater concern about European tariffs, which makes sense as many European manufacturers have U.S. manufacturing, assembly and distribution.
As noted, mobile hydraulics seems to be bearing the brunt of the tariff concern. NFPA’s latest data shows a 20% drop in mobile hydraulic shipments compared to last year, with orders trending even lower. Conversely, pneumatics and industrial hydraulics shipments are holding steady or even showing signs of growth.
While we wait and see how these chang-
ing tariffs will impact the industry, I do expect to see more reshoring and near-shoring in the future. While more manufacturers continue to build plants in Mexico, China’s numbers have stabilized and even declined. Alles said more European companies have explored NFPA membership. As American fluid power companies increase stateside production, perhaps we’ll see more international companies explore production here in the future.
It's an optimistic viewpoint and one I like to hold onto — I try to be a glass half-full kind of person. As I’ve heard for years at various NFPA, FPDA and NAHAD conferences, the U.S. is not immune to volatility, but as the biggest economy in the world, we still have an attractive manufacturing base.
The tariffs may change again today, tomorrow, and next week. As I write this, the Trump administration is saying they’re about to announce a trade deal with China. But we will wait. We will keep adapting to the changes that may come and continue to power the machinery that makes the world go around. FPW
New machines highlight sustainability and productivity bauma brought together machinery makers and component experts to show modern, efficient mobile design options.
32 INDUSTRIAL HYDRAULICS
Contamination — still the biggest problem for fluid power systems
Industrial systems, whether pneumatic or hydraulic, must prevent a variety of contamination sources to run reliably.
41
IVT SHOW PREVIEW
Registration open for growing iVT Expo
With more exhibitors and a growing conference platform, the iVT Off-Highway Vehicle Technology Expo promises two educational-filled days August 20-21 in Chicago.
EDITORIAL
PRODUCTION
VP,
Art
Art
Audience
atanner@wtwhmedia.com
PRODUCTION SERVICES
Customer Service Manager
Stephanie Hulett shulett@wtwhmedia.com
Customer Service Representative Tracy Powers tpowers@wtwhmedia.com
Customer Service Representative JoAnn Martin jmartin@wtwhmedia.com
Customer Service Representative Renee Massey-Linston renee@wtwhmedia.com
Customer Service Representative Trinidy Longgood tlonggood@wtwhmedia.com
MARKETING
VP, Operations Virginia Goulding vgoulding@wtwhmedia.com
Digital Marketing Manager Taylor Meade tmeade@wtwhmedia.com
SALES Ryan Ashdown 216-316-6691 rashdown@wtwhmedia.com
Jami Brownlee 224.760.1055 jbrownlee@wtwhmedia.com Mary Ann Cooke 781.710.4659 mcooke@wtwhmedia.com
Jim Powers 312.925.7793 jpowers@wtwhmedia.com
Courtney Nagle 440.523.1685 cseel@wtwhmedia.com
LEADERSHIP
CEO Matt Logan mlogan@wtwhmedia.com
Co-Founders Scott McCafferty Mike Emich
SUBSCRIBER SERVICES: To order a subscription please visit our web site
Josh Cosford • Contributing Editor
Are your hydraulic choices wrong?
THERE’S
AN UNFORTUNATE TREND
these past few years where the social meta is increasingly binary. No, I’m not talking about gender. I’m a libertarian and live my life hon oring the late, great Shock G from Digital Underground; Doowutchyalike. The binary I’m speaking of is the decreasing diversity of the sociopolitical environment equivalent to playing video games in 4K and downgrading to 1-bit electron tubes.
It seems we went from being free minds with a broad spectrum of thoughts, ideas and opinions to being juxtaposed in the unification of two ideas only. If you don't believe a, b and c while opposing x, y and z, then you're a fraud and traitor and should be denied participation in reindeer games. What's that? You're a prolife atheist? Huh? You hate guns and social ism? Say what? You love Joe Rogan and The View? Off to the Island of Misfit Toys for you!
Indeed, tribalism manifests through sports, nationality and politics but becomes dangerous when taken to extremes. You're probably wondering what any of this has to do with fluid power. As much as I love writ ing about what I think is the best way to design, maintain and use fluid power, I have to remind myself that for every opinion piece
HAWE Hydraulik is announcing a new expanded cartridge valve offering! In addition to HAWE’s traditional cartridge valves, PMVE, RK, CLHV, OSCA, BVE, and CDK, we now have many more cartridge valves with a wide range of flows and in a variety of cavities including the most popular T-**A and SAE cavities.
Advantages and benefits:
■ High degree of interchangeability.
■ Highly engineered and reliable components.
■ Flexible solutions in customized manifolds.
■ Cost competitive solutions.
■ Stocked locally in Bethlehem, PA.
■ Perform same pressure, flow, and directional control functions as conventional hydraulic valves.
HAWE Hydraulik manufactures the highest quality hydraulic components, constructed to minimize space and maximize product durability for the mobile, industrial, marine, and oilfield markets.
Learn More:
HAWE is your complete custom hydraulic solution provider! www.HAWE.com | info@haweusa.com | 704-509-1599
Mary C. Gannon • Editor-in-Chief
Hydraulic cylinders provide the safe lifting on self-propelled inloader
AT
BAUMA IN APRIL, Combilift, an Irish material handling equipment manufacturer, unveiled its newest innovation — a self-propelled inloader called the COMBi-SPI. This launch marks a significant milestone in the transport of high loads, such as precast concrete, wall panels or glass A-frames, within production facilities and yard environments.
The COMBi-SPI is an efficient, maneuverable and cost-effective alternative to expensive trailers and trucks. The objective during the design inception in 2022 was clear: to create a versatile solution capable of handling 30-ton loads on industry standard Inloader Pallets with superior visibility, agility, and ease of operation.
The collaboration with Spaansen, a specialist in precast concrete, influenced the design through to the final stages. Early prototypes focused on reducing overall length and width and enhancing maneuverability for working in busy production facilities. However, the project took a significant turn when Spaansen opted for a fully electric model mid-development. This shift required a complete redesign to integrate the electric wheel motors as well as fit the interchangeable batteries into the legs of the machine.
Although electrics can power the machine, hydraulics are crucial to the safe holding of the load. Six hydraulic cylinders are used in a master/slave arrangement, with three cylinders used on each side to synchronize the lift. The weight limit for the cylinders is 40 ton, far surpassing the required weight of 30 ton required by the machine. The cylinders are integral to sliding load supports, which are easily adjusted manually to their required position in support of various load dimensions. These load supports can also operate individually or simultaneously, thanks to cylinder control from within the cab.
Check valves help provide the clamping action required of the cylinders. Hydraulic cylinders are also used in the steering system,
SIX HYDRAULIC CYLINDERS PROVIDE THE LIFTING AND HOLDING FUNCTIONS ON THE SLIDING LOAD SUPPORTS ON THE COMBISPI SELF-PROPELLED INLOADER.
COMBI-SPI SELF-PROPELLED INLOADER CAN HOLD LOADS UP TO 30 TONS, SIMPLIFYING THE TRANSPORT OF LARGE, HEAVY LOADS SUCH AS PRECAST CONCRETE, WALL PANELS OR GLASS A-FRAMES, WITHIN PRODUCTION FACILITIES AND YARD ENVIRONMENTS.
ensuring safe and precise control. Additionally, a hydraulic lifting platform smoothly raises the load into position quickly and accurately, and ensures quick set-down as well.
An engineering spokesperson said the 30-ton design is standard for now, “but at Combilift, our innovation is driven by our customer requirement, so if a future customer requires higher capacity, then we will look at providing a solution for them.”
Other key features include:
• Side-facing cab: Provides operators with a clear, panoramic view of both the load and
A HYDRAULIC LIFTING PLATFORM SMOOTHLY RAISES THE LOAD INTO POSITION QUICKLY AND ACCURATELY, AND ENSURES QUICK SET-DOWN AS WELL.
“At Combilift, our innovation is driven by our customer requirement... we will look at providing a solution for them.”
A BETTER MACHINE? WANT TO BUILD
GO TO THE SOURCE.
Innovation starts with Bosch Rexroth and HydraForce. Our expert application engineers design efficient electro-hydraulic systems, delivering compact hydraulic solutions that enhance machine performance. Whether it’s an upgrade, redesign or new motion control application, rely on our global team to help you gain a competitive edge.
direction of travel, ensuring enhanced safety and precision.
• Pivoting front dual-wheel configuration: Eliminates the need for suspension, optimizes stability and gives a tighter turning circle.
• 300-mm ground clearance: Designed for both concrete and gravel yards, offering reliability across diverse work environments.
• Power options: Available in electric (with interchangeable battery system), diesel, and LPG, catering to different operational needs.
• Compact yet powerful: The short chassis enhances load support, maintains a low center of gravity and offers more maneuverability, especially while operating within production facilities.
With unmatched maneuverability and faster operational speed, the Self-Propelled Inloader transforms yard-based logistics by eliminating the reliance on multiple trailers and shunters, significantly enhancing efficiency and reducing operational costs for businesses handling oversized, high loads.
DESIGN
“This project showcases Combilift’s commitment to innovation and customer-driven design,” said Josh Moffett - Heavy Equipment Manager at Combilift. “We’ve leveraged decades of expertise in specialised transport machin-
ery to develop a state-of-the-art solution that meets the evolving needs of the concrete and glass industries.” FPW Combilift combilift.com/spi
Mary C. Gannon • Editor-in-Chief
A PANORAMIC CABIN PROVIDES HIGH VISIBILITY FOR SAFE OPERATION AND TRANSPORT OF LOADS.
Rachael Pasini • Senior Editor
Save costs by managing “energy gobblers”
THE ENERGY SERVICES ACT is a key piece of legislation in Germany that aligns with the EU Energy Efficiency Directive. It mandates that large enterprises conduct regular audits to improve energy efficiency and reduce overall consumption or potentially face fines up to €50,000.
Such legislation drives technology innovation and increases the adoption of efficient machinery, IoT-based monitoring, and automated systems to address audit findings and energy goals. For compressed air systems, this includes implementing intelligent control solutions to integrate data sources and identify opportunities for energy savings.
According to a study by Radgen and Blaustein, compressed air systems can account for 10% of Germany’s industrial electricity consumption. Manufacturers are well aware that such consumption includes air losses due to leaks at joints, valves, worn hoses, and other components throughout the system. Without regular monitoring and maintenance, leaks can remain undetected, continuously wasting the system’s energy and driving up costs.
“In many cases, leakage is more than 30% of the compressed air,” said Patrick Schuckenböhmer, sustainability coordinator at Boge Kom-
The Radgen and Blaustein study shows that approximately only 45% of compressed air consumption meets air system demands. The majority of the rest is from leakage and unnecessary excessive usage.
pressoren. “Unlike water or oil leaks, air leaks leave no marks on the floor. The cost of the electricity generated by leakage usually disappears in the electricity bill for the whole factory, and as long as there is enough compressed air to work with, no one complains. But the cost can be significant, even in smaller companies. If a com-
pressor with 25 kW electric power consumption is running 350 hours per year just because of leakage, at a price of €0.2 per kWh of electricity, this adds up to around €1,750 per year.”
The Radgen and Blaustein study shows that approximately only 45% of compressed air consumption meets air system demands. The majority of the rest is from leakage and unnecessary excessive usage.
Oftentimes, users try to compensate for air losses while still meeting air demands by operating systems at higher pressures. However, as Schuckenböhmer put it, “an air pressure too high causes losses; a pressure too low, even for a short time and only in one branch of the compressed air system, can cause damage.”
Larger manufacturers typically have a superordinate control system that monitors and optimizes air demand and related parameters in multiple compressed air systems. However, in small and medium-sized companies without superordinate control, measuring leakage remains a manual process. Boge developed and integrated a leakage monitor in the control of its compressors, especially for these systems, to manage what it calls “energy gobblers.”
“In smaller companies, the person responsible for the compressed air system has probably heard of energy saving and leakage, but does not know how much leakage in the compressed air system costs. The leakage monitor can show them,” said Schuckenböhmer. “The idea behind the leakage monitor is simple: If there is no useful air demand within a specific time slot, then all air demand during this time is leakage. Then, you can sit next to the compressors for a few hours with a stopwatch, count the running times when air is being compressed, add up the compressed air, and calculate.”
Schuckenböhmer provided an example: 18 min of operation of a 2 m³/min compressor in 3 hr with no useful air demand results in 18 min / (3 * 60 min) * 2 m³/min = 0.2 m³/min leakage. Since leakage is usually almost the same
BOTH PHOTOS SHOW COMPRESSED AIR LEAKAGE
Solutions Under Pressure
Check
Needle Valves
Flanges & Adapters
Bar & Custom Manifolds
Pressure Gauges & Snubbers
SSW Power Unit Systems
Transfer Pumps
Industries Served:
• Oil & Gas
• Industrial Hydraulics
• Mining
• Forestry
• Chemical & General Processing Plants
• Medical
• Aerospace
• Factories
• Mobile Equipment
• Defense
• Machine Tool
• Testing Equipment
• Ocean Depth Technology
• Automotive
• Food Processing
• Agriculture
• Industrial
• Aviation
• Petrochemical
•
throughout the year, manufacturers can calculate the cost per year.
“The downside of this method is that nobody likes to sit next to the compressors for a few hours at night or on a Sunday,” he said. “So, this counting task is done by the Base and Focus 2.0 controllers, except the Focus versions for scroll compressors or Boge turbocompressors. It has been part of the standard control software since 2012, and older controllers of these types can be upgraded with this software.”
Additionally, interlocking control, such as the Airtelligence Provis 3, helps make the entire compressed air management efficient and adaptable. The software integrates an unlimited number of components and, based on requirements, determines the optimal compressor configuration for a specific time during operation. The smart tool is particularly suitable for highly fluctuating compressed air requirements and mixed compressor combinations. It also continuously optimizes energy consumption, where a 1-bar reduction saves
as much as 10% in energy costs. Another important area where companies can lower energy costs is heat recovery. Up to 94% of the energy consumed during compressed air generation can be reused as heat,
with an average payback period of four months. In this process, Boge diverts the waste heat from the compression process, specific to each compressor. It can then be used to heat rooms or water, for example. Compressors manufac-
tured by others can also be retrofitted with Boge’s heat recovery system.
“The two simplest systems, which are used most often, are an air duct that brings warm cooling air from a compressor into a large room of the factory in winter, without any sensor, and a heat exchanger that uses the waste heat from the compressor to heat the water of the heating system in a factory, coming back from its heating task with a lower temperature and going into the boiler of the central heating, giving the temperature necessary for heating the factory. There is no sensor or control system. The waste heat is transferred to the hot water, if available, and the central heating boiler provides the additional heat. Of course, more complex systems are possible,” said Schuckenböhmer. FPW
Boge boge.com
Source: Radgen and Blaustein, Compressed Air Systems in the European Union. Energy, Emissions, Savings Potential and Policy Actions, 2001.
HAZARDOUS LOCATION TRANSMITTERS
HEAT GENERATED DURING AIR COMPRESSION CAN BE REUSED TO HEAT FACTORY ROOMS OR WATER.
Why space matters in mobile hydraulics
WHEN YOU STEP ONTO THE FLOOR
of an industrial plant, the vast scale and constant hum of activity are undeniable. Massive hydraulic presses and intricate pipework stretch across the floor with the kind of freedom this scale allows. Space is abundant and equipment can be as robust and heavy as the job demands. It’s easy to take that freedom for granted until you're working with a design where every inch counts.
Mobile applications face a different reality. Every valve, pump, and motor must be carefully chosen to keep the machine working hard without being weighed down by its own systems.
With every function competing for space, there’s little room for excess. That’s why engineers must rethink the components being used to maximize fuel efficiency, space, mass, cost, and more. Here are three areas where compact alternatives can make a big and efficient impact.
Rotating parts
Designing systems to rotate, lift, or steer loads in mobile equipment always raises the same question: how do you squeeze the most force and control into a compact package? Traditional configurations like rack-and-pinion actuators,
cylinders, and levers can certainly get the job done, but often at the expense of valuable real estate.
Helical spline actuators help solve this problem. The internal mechanisms are straightforward. A helical splined shaft works in tandem with a sliding piston to convert linear movement into rotation. The splined teeth create a tight fit between components, resulting in a uniform and compact build.
For these reasons, helical spline actuators are noticeably shorter than some of the previ-
HELICAL SPLINE ACTUATORS ARE NOTICEABLY SHORTER THAN RACK-AND-PINION, CYLINDER AND LEVER DESIGNS.
ously mentioned alternatives. Let’s consider an application that requires 360° of rotation with 3,540 lbf-in (400 Nm) of torque at 3,045 psi (210 bar). Using a rack-and-pinion actuator could require almost a foot and a half of installation space, while a helical actuator could deliver the same performance in just 4 in., taking up four times less space. Helical spline actuators have a larger profile in terms of height and width. That said, savings in linear space are often far more valuable in real-world applications where depth is the limiting factor in design.
Hallie Riley & Victoria Lower • IC Fluid Power COMPACT ALTERNATIVES CAN MAKE A BIG AND EFFICIENT IMPACT ON MOBILE MACHINERY COMPONENT SELECTION.
RATHER THAN A SOLID, HEAVY SPHERE, BUTTERFLY VALVES OPERATE WITH A THIN DISK ON A STEM WHICH YIELDS THREE MAIN BENEFITS: A SMALLER FOOTPRINT, MORE DESIGN FLEXIBILITY, AND COST SAVINGS.
Shutoff and regulating flow
Integrating emergency shutoff isn’t just best practice — it’s essential. Excavators and drill rigs often operate near sensitive waterways and ecosystems where even a small hydraulic leak could have serious environmental implications.
For years, ball valves have been the standard for flow regulation due to their affordability, easy actuation, and reliable sealing. Butterfly valves offer the same performance but differ mainly in cost and size. As designs become more sophisticated, saving space can be just as important as the cost.
Unlike ball valves which use a solid, heavy sphere, butterfly valves operate with a thin disk on a stem. The slim profile of the butterfly valve yields three main benefits: a smaller footprint, more design flexibility, and cost savings at larger sizes.
Butterfly valves are notably shorter and lighter than ball valves, especially as the pipe size increases. For a small 1.25 in. pipe, a typical ball valve is about 3.7 in. (95 mm) long, while a butterfly valve is about 1.4 in. (35 mm) making it roughly 60% shorter. On a 4 in. pipe, a butterfly valve can be as thin as 1.8 in. (45 mm) with a
PRESSURE
INTENSIFIERS BOOST PRESSURE LOCALLY WITHIN A SPECIFIC CIRCUIT OR FUNCTION, RATHER THAN THROUGHOUT THE ENTIRE SYSTEM.
weight of 3.5 lb (1.6 kg). When compared to a 7.5 in. (190 mm) ball valve, the ball valve is almost four times heavier with a weight of 12 lb (5.5 kg).
The compact profile frees up valuable space, meaning system designs can include larger
tanks or more flexibility when routing hoses and incorporating other parts into the system.
As the valve size increases, the cost advantage of butterfly valves becomes more pronounced. For example, on a 4 in. pipe, a ball valve can cost the same or even twice as much as a butterfly valve. Butterfly valves can be equipped with a proximity switch to ensure the hydraulic pump does not start if the butterfly valve is closed.
Intensifying pressure
When greater force output is needed, either the area or pressure must be increased. Since area is not always a viable option in mobile hydraulics, increasing system pressure becomes the most practical solution. This can be done in two ways.
One solution is upgrading to a pump with a higher pressure rating. This enables the system to maintain elevated pressure throughout all circuits, supporting continuous high-force operation.
Another option is using a pressure intensifier. This device is designed to boost pressure locally within a specific circuit or function, rather than throughout the entire system (though they are capable of doing so). This targeted approach allows you to achieve the necessary force exactly where it’s needed without the expense or space requirement of bulky equipment like high pressure pumps.
Many applications in construction and material handling could optimize space and efficiency with pressure intensifiers. For example, hydraulic cylinders in a mobile crane may need an output of 3,625 psi (250 bar) to lift loads as heavy as 20,000 lb (9,090 kg). Integrating a pressure intensifier could directly boost cylinders, while occupying just 4 in. of space at the same or even half the cost of a high-pressure vane pump.
Design considerations in mobile hydraulics go beyond space, of course. However, size is one of the most important aspects of decision making due to the constraints it imposes. Manufacturers and system engineers can keep machines lightweight without having to sacrifice performance by using compact, smarter alternatives to traditional hydraulic parts.
IC Fluid Power icfluid.com
Josh Cosford • Contributing Editor
Preventing microbes in hydraulic oil
MICROBES ARE NOT COMMON CONTAMINANTS IN HYDRAULIC SYSTEMS, BUT WATER CAN ENCOURAGE GROWTH. DRY OIL PREVENTS THIS TYPE OF CONTAMINATION.
MICROBES AREN’T THE MOST COMMON contaminant in hydraulic oil, but they do become a problem when conditions are ripe for their proliferation. Anaerobic bacteria of various forms are the most common to be found within hydraulic fluid, although it’s not unheard of to see fungi (molds and yeasts) in very specific conditions. Regardless of the microbe species, they’re an annoying contaminant to deal with.
Microbes form almost exclusively in watercontaminated hydraulic fluid because, like most Earthly lifeforms, they require H20 to survive. The warm, wet environment of a water-saturated reservoir makes a perfect home for selfreplicating organisms to flourish. You must consider that everyday hydraulic systems do well at preventing microbial growth because they do not provide what the little prokaryotes need — water, food and stagnation.
The stagnation component is where most hydraulic systems gain the advantage over microbes — the pressure of circulating through the work lines of a machine certainly kills every lifeform outside of tardigrades. And the ones that make it are unlikely to find a restful place
to reproduce. If you run hydraulic machinery in warm climates with the potential for water ingress, pay special attention, especially if your machines ever sit idle for long periods.
Microbial growth harms your hydraulic system in a few ways. During metabolization, microbes create acidic waste, which accelerates the chemical degradation of your oil. The result could be increased viscosity and degraded additives, which lead to poor machine performance, reduced efficiency and possible cavitation. Additionally, biofilm and sludge may form, providing their own symptoms, such as restricted flow or easily clogged filters that prematurely bypass.
Just like all forms of hydraulic fluid contamination, prevention is the best medicine. If you keep your hydraulic system dry, it’s unlikely microbes can grow. However, if you experience chronic water intrusion, there are common “drop-in” solutions.
A desiccant breather cap will trap moisture inhaled by your reservoir, keeping overall humidity down in what is otherwise a sealed system. With many conditions and under cer-
tain circumstances, the humidity of the air and the oil will equalize. Excessive air humidity will transfer water molecules to the oil, increasing the likelihood of free water to occur when atmospheric temperatures and pressures drop. By installing a desiccant breather cap, the air is dried before it can contaminate the hydraulic oil inside the reservoir.
Of course, should free water find its way into your hydraulic fluid, it must be removed as quickly as possible. Water-absorbing filter elements are an inexpensive option for removing free water from oil as the fluid passes through the assembly. Although old school waterremoving elements use natural materials like cellulose, modern technology uses synthetic, superabsorbent polymers to achieve another level of dryness.
There is no such thing as oil being too dry, and because microbes require water to live and reproduce, there is no downside to ensuring water is prevented from contaminating your hydraulic system. Even if microbial growth isn’t a problem for your machine, dry oil allows your machine to run at its best, anyway. FPW
Outlining processes ensures skills are understood, step-by-step
WRITING OUT INSTRUCTIONS FOR A TASK HELPS TO ENSURE THEY ARE A COMPLETE OUTLINE TO PROPERLY FINISH A JOB. THEY ALSO CAN BE ADDED TO YOUR SERVICE MANUAL OVER THE YEARS.
industry is facing
IF YOU HAVE BEEN FOLLOWING this series over the last few months, you’ve learned about the importance of creating a formal learning process with your junior technician, and how to create proper learning objectives. While these are all important parts of the process, these are really the main aspects of the pre-planning process. While many may see this as wasted time, I assure you pre-planning is important to make sure you create a successful program to give your senior technicians the tools they need to succeed.
This month, I wanted to discuss a simple trick that will allow your team to excel when determining the best method to pass down information they have stored in their brains over the years. This is the main goal with any training program, to ensure information is passed to new junior technicians and not forgotten. I have been in many training situations over the years and have noticed one of the great-
“This is important: never assume the people you are training understand or know how to do everything. Always assume they know nothing until you can identify exactly how advanced their learning skills are. ”
est failures is simply forgetting to discuss all the information when teaching a new technique or skill. I have observed others teaching someone how to do something and they often don’t mention simple steps because they assume the other person already knows.
This is important: never assume the people you are training understand or know how to do everything. Always assume they know nothing until you can identify exactly how advanced their learning skills are. After you have gauged where they are on their learning journey, you can finely tune what you deliver to make the process more efficient. But until this happens,
it is very important not to assume. I use a simple trick from schoolchildren which is a great exercise on creating a procedural outline for a new skill or technique that you are trying to teach. This process, when done with school children, involves having kids write down the steps involved in creating a grilled cheese and then having the teacher follow these steps literally. If you have ever seen these online you have seen the hilarity that ensues. This is a great tool to go through with your technicians-in-training. It simply starts with a piece of paper and a pen — yes a piece of paper and a pen. Do not reach for the computer. Paper
Devin Purcell • Technical Trainer
Editor’s note: In this multi-part series, Devin Purcell continues to tackle the skills shortage that the fluid power
and offer creative solutions to address this challenge.
“The greatest by-product of this training process beyond the skills that it provides your technicians in mentoring is the amazing outlines that you can add to your process manual. ”
is much more tactile and gives us an opportunity to get “messy” during the process.
Let's use a simple vehicle oil filter change as an example that everyone will be familiar with, no matter what part of the industry you work in. Grab a pen and a piece of paper, take 15 minutes, and outline the process now.
WHEN CHILDREN GIVE GRILLED CHEESE INSTRUCTIONS TO A TEACHER, THE RESULTS CAN BE QUITE ENTERTAINING AND SOMETIMES DISASTROUS, LIKE THIS AI-GENERATED PHOTO OF A NOT-SO-DELECTABLE MEAL. WITHOUT DETAILED INSTRUCTIONS, THE SIMPLE PROCESS OF CHANGING AN OIL FILTER CAN HAVE
*Please stop reading now. If you cheat and follow the next steps you will ruin the process.*
So, now that you are finished, let’s take a quick look at what you came up with.
When you look at the list of steps you created, could a complete beginner with no knowledge of doing the job complete the repair?
For example, you might write a simple step such as “install the oil filter.”
For an experienced technician this description works. However, if you are not familiar with filter installation, it needs to be covered in much greater detail.
Here is a revised version of the step: Make sure the oil filter is the correct part number for the year and engine size of the vehicle. Inspect the oil filter and ensure that there is no debris in the threads of the filter. Double check that the O-ring is present and in good condition. Install the oil filter on the filter spud and turn in a clockwise direction to tighten. Once the filter O-ring is touching the filter base and is snug, turn ½ to ¾ of a turn. Clean any excess oil that was spilled during the process.
This is the type of detail that you are look-
ing for. In the first example, we assume that the person installing the oil filter already knows how to install the filter based on how simple the instruction is. This is the type of assumption that we cannot make before we know where they are on their learning journey.
If we assume that the person knows how to do this, they may fill in the blanks on their own and decide to complete the job as they assume the job should be completed. As you can imagine, this has the potential to create catastrophic results.
These step-by-step outlines are not used to teach the junior technician; they are to be an exercise to show a senior technician the detail that they need to provide the technicians that they are training. This training exercise can be used for each job that you are teaching, or it can be used to bring awareness to the training technician.
The greatest by-product of this training process beyond the skills that it provides your technicians in mentoring is the amazing outlines that you can add to your process manual. This increases your technician's knowledge as the years progress and more and more step-by-step processes are added to your manual.
Let me provide you with a simple challenge. Build on the oil change example that I have given and let’s see how technical and thorough
your instructions can be. I know that some of you will make my “thorough” outline look like child's play.
The challenge is on you. Send me your examples at devinj.purcell@gmail.com
If you would like to use another repair or skill as an example, I would love to see what you come up with as well. FPW
Ron Marshall • Contributing Editor
Compressed air fail: Blowing
A COMPANY PRODUCING VINYL SIDING
was using a lower pressure blower to blow water off the product as it came out of its production machine. But the blower failed, and the staff quickly rigged up some compressed air nozzles consuming about 50 cfm. An air auditor noticed this misuse and flagged it as an inappropriate use — costing
pressures exceed OSHA’s 30 psi safety limit or if debris is blown into the air. Particles dislodged during cleaning can become airborne and pose risks to workers’ eyes, skin, or respiratory health. From a cleanliness standpoint, blowing contaminants off the belt doesn’t truly remove them — it simply redistributes them to other areas of the plant, potentially
about $6,000 per year in energy costs.
Using compressed air to blow a conveyor belt clean is a common practice in industrial settings, but it comes with several significant disadvantages that often outweigh its convenience. One of the biggest drawbacks is energy inefficiency.
Compressed air is one of the most expensive utilities in a plant, requiring about 7 to 8 hp of electrical energy to produce just 1 hp of work. Blowing applications, particularly when using open pipes or unregulated nozzles, waste a tremendous amount of energy. When this method is used frequently or continuously throughout the day, the operating costs can add up quickly, especially if the system has leaks — an issue present in most facilities. Beyond inefficiency, there are important safety concerns. Using compressed air for cleaning can be hazardous, particularly if
causing cross-contamination issues, especially in sensitive environments like food processing or pharmaceuticals.
There are also better alternatives available that are more efficient and effective. Mechanical scrapers, brushes, or vacuum systems can clean conveyor belts thoroughly without the high energy use or safety concerns. In cases where air flow is necessary, blower-powered air knives offer a far more energy-efficient solution than compressed air. Overall, replacing compressed air for belt cleaning is often considered low-hanging fruit for energy savings and operational improvement.
The siding company decided the high cost of the compressed air blower could easily be saved if they repaired the old low-pressure blower. Costs for the repairs were $3,000, savings that was recovered in six months.
NEW MACHINES HIGHLIGHT SUSTAINABILITY AND PRODUCTIVITY
Bauma 2025, held recently in Munich, confirmed its reputation as the world’s premier construction-equipment exhibition. More than 600,000 visitors from 200 countries showed up to see the latest offerings from 3,601 exhibitors. The emphasis was on new machines, with a focus on sustainability and productivity — including those powered by alternative drives and fuels — and on digitally controlled systems that aid operator productivity or eliminate the driver altogether. Here are just a few of the new introductions.
BY: KEN KORANE
BAUMA HOSTED
600,000 VISITORS AND 3,601 EXHIBITORS, WITH COUNTLESS NEW MACHINES AND PRODUCTS LAUNCHED TO MOVE THE MOBILE MACHINERY INDUSTRY FORWARD.
bauma brought together machinery makers and component experts to show modern, efficient mobile design options.
1. Emissions-free aerial lifts
With construction being one of the major contributors to carbon emissions worldwide, the push for contractors to adopt decarbonizing measures is becoming critical. The question is how to effectively adopt zero-emission technologies for construction, particularly in settings where charging infrastructure is scarce.
Without adequate charging options, many construction projects may rely on diesel-powered MEWPs (mobile elevating work platforms) or resort to charging electric MEWPs using diesel or hybrid generators, all of which significantly contribute to CO2 and particulate emissions, and noise pollution.
Niftylift has addressed this challenge by introducing the SP50 H2E HydrogenElectric aerial lift at bauma. The machine, according to company officials, is a revolutionary MEWP designed for zero-emission operation using hydrogen fuel.
Powered by an onboard hydrogen fuel cell, it offers:
• Zero-emission operation, emitting only water vapor.
• Extended runtime, even in areas without charging facilities.
• High efficiency, combining hydrogen power with an advanced all-electric drive.
• Simple hydrogen fuel bottle replacement.
Niftylift's H2E system, powered by a
single G20 Hydrogen bottle, fully charges the batteries. The G20 bottle is easy to swap and provides a clean, consistent, onsite solution for long-term use, and helps achieve operational net-zero goals.
The self-propelled SP50E, with an allelectric drive and hydrogen fuel cell technology, can run for over five days on a single charge, according to Niftylift. Aligned with the company’s other all-electric models, this pioneering technology allows for uninterrupted zero-emission operations, even without access to charging stations.
2. Hydrogen-powered prototype
Hyundai Construction Equipment’s bauma exhibit included a preproduction version of the manufacturer’s hydrogen fuel cellpowered HW155H 5-ton wheeled excavator. The company’s aim was to showcase its innovative fuel cell technology for carbonfree operation.
A single hydrogen fuel cell delivers 90 kW of power which is sent to the electric drive motors and electrically driven hydraulic pumps. Onboard fuel H2 fuel capacity reportedly supports up to 12 hours of operation, while refueling takes about 10 to 20 minutes.
The advanced low-pressure, high-density hydrogen storage system offers sizable capacity while improving safety. Developed
in collaboration with Hyundai Motor Co., the HW155H demonstrates all-day usability, safety, and sustainability while maintaining the performance of a diesel-powered machine. With mobile refueling options, Hyundai aims to make hydrogen a viable energy source for construction projects worldwide.
3. Hydrogen combustion
While the construction industry increasingly looks to switch from traditional diesel engines to more environmentally friendly drives, the central question is always how the energy gets to the construction site and into the machine, according to Hitachi Construction officials.
The company, in a joint venture with Kiesel Technology, is looking to meet the challenge by offering a range of zero-emission excavators. Nine models were showcased at bauma, mostly battery-electric machines sized from 1.7 to 14 tons.
However, one of the excavators, the ZE300 H2, offers a different route by showcasing the potential of hydrogen as an alternative clean fuel. This 30-ton concept excavator is groundbreaking and has been designed for heavy-duty work in environmentally sensitive areas, said Hitachi officials.
The hydrogen engine is supplied by Deutz and hydrogen storage is integrated into the rear of the ZE300, replacing the counterweight. This allows for easy access to the engine compartment for maintenance and rapid refueling.
The Deutz TCG 7.8 H2 hydrogen combustion engine is based on the established TCD 7.8 diesel engine. It is just as powerful,
HYUNDAI'S HW155H WHEELED EXCAVATOR DELIVERS 90 KW OF POWER TO THE ELECTRIC DRIVE MOTORS AND HYDRAULIC PUMPS.
NIFTYLIFT'S SP50 H2E HYDROGENELECTRIC AERIAL LIFT IS DESIGNED FOR ZERO-EMISSION OPERATION USING HYDROGEN FUEL.
HITACHI ALSO HIGHLIGHTED HYDROGEN DESIGNS. ITS ZE300 H2 IS A 30-TON CONCEPT EXCAVATOR WITH A DEUTZ HYDROGEN ENGINE AND REAR-MOUNTED STORAGE TO ELIMINATE COUNTERWEIGHT NEEDS.
durable, and reliable, said the company.
Engine efficiency depends largely on its design. For the H2 hydrogen engine, Deutz engineers specifically analyzed the injection system components to ensure that they meet requirements for use in off-highway applications. The outcome is a sophisticated technological solution that enables drives operation in commercial vehicles. With hydrogen engines, however, there is a possibility that NOx emissions could spike in isolated operating states. In this case, most NOx emissions are eliminated through the use of an after-treatment system.
The company said the engine offers excellent energy efficiency combined with high dynamic response, while maximizing the power and flexibility to suit customers’ applications. Max rated power is 220 kW (2,200 rpm) with max torque of 1,000 Nm (1,400-1,600 rpm). H2 consumption is about 19 kg/hr at max power.
4. Electrics go big and small
While numerous alternatives to diesel machines could be found throughout bauma, one machine was hard to miss: Komatsu’s electrically powered PC700011E hydraulic mining excavator. Towering about 60 ft high with an operating weight of 750 tons and a bucket capacity of 50 yd³, the machine is said to offer the powerful
digging force of high-performance diesel machines with a lower carbon footprint.
The PC7000-11E matches well with the company’s range of large mining trucks, reducing truck passes and increasing efficiency and productivity of mining operations.
Aligned with Komatsu's sustainability focus, the electric drive is designed to reduce carbon emissions by up to 95% compared to its diesel counterpart. Benefits of electrically powered hydraulic mining excavators include reduced operating costs, elimination of diesel fuel, and significant reduction in parts and maintenance costs, resulting in up to 50% savings in the total cost of ownership compared to conventional Tier 4 diesel drives.
A fully automatic cable drum is designed for efficient operation of the electrically driven excavator. Automatic cable winding makes maneuvering in the pit safer and easier. Simplified electric machine control enables fast troubleshooting and maintenance of the electrical system, resulting in increased overall availability of the machine.
Like most everything on this massive machine, the hydraulics are impressive. Two gearboxes each drive three identical pumps with rated flow of 1,640 gpm at a relief valve setting of 4,495 psi. Swing flow rate is 273 gpm.
The four-circuit system features a load-
limiting governor with oil delivery summation to the working circuits and incorporates pressure cut-off control. Hydropilot prioritizes hydraulic flow giving smooth hydraulic response, simple hydraulic system layout, and fewer components.
According to Komatsu, the growing demand for decarbonization in the mining industry has many customers setting ambitious greenhouse gas (ghg) reduction targets. Electrified excavators deliver the same mobility, power, and productivity as diesel machines, while helping users meet their emissions goals. By combining operational efficiency with environmental responsibility, electrified equipment such as the PC700011E plays a vital role in driving the mining industry’s transition to more sustainable practices.
At the other end of the spectrum, Komatsu presented three new electric mini excavators in live demo at bauma 2025, the PC20E, PC26E, and PC33E. (All three could fit in the bucket of a PC7000-11E excava-
HITACHI
KOMATSU'S DISPLAYS RAN FROM MASSIVE WITH ITS PC7000-11E ELECTRICALLY POWERED 60-FT MACHINE, ABOVE, TO ITS MINI ELECTRIC EXCAVATORS, INCLUDING THE PC2E, RIGHT.
tor.) The smallest, a two-ton machine, is powered by an 11.8 kW electric motor and a 23.2 kWh battery pack. It can fast-charge in 1.8 hr with a 400 V external dc charger.
“Komatsu is committed to developing innovative and sustainable technologies that meet the evolving needs of our customers,” said Emanuele Viel, Group Manager for the Utility line at Komatsu Europe. “The new electric mini excavators are a confirmation of this ongoing commitment, offering zero emissions operation without compromising on performance.
“Komatsu set a challenging target of becoming carbon neutral by 2050, which means virtually eliminating CO2 emissions not only from our own sites and from the use of our products, but also from customers’ sites. Komatsu aims to meet the needs of our customers by introducing a diverse range of electrified construction equipment.”
5. World-first electric articulated haulers
Breaking new ground in electrification, Volvo Construction Equipment introduced the powerful A30 Electric and A40 Electric – the world’s first serial-produced batteryelectric articulated haulers of their size.
Offering the same off-road performance as conventional models, the two new machines match zero emissions with world-class hauling for a range of segments including quarrying, mining and construction. With a payload of 29 tons and
39 tons respectively, these machines are now among the largest in Volvo CE’s electric portfolio.
Mats Sköldberg, Head of Technology for Volvo CE, said “These electric haulers mark a major step forward in our ambition to decarbonize construction, combining the same unbeatable performance our customers know and love, with a more sustainable operation. As the world’s first battery powered articulated haulers of their size class, we are proud to continue to evolve our portfolio by bringing our world-class electric technology into a brand-new segment.”
Relying on lithium-ion batteries, the electric haulers are designed to offer a runtime of 4 to 4.5 hours across most applications, though high-energy jobs may require more frequent recharging. Ideal applications include downhill load carrying and uphill empty runs, tunnel work, and quarries and underground operations where emission reduction is critical.
Fast charging from 20-80% in around one hour is possible when using dc charging with a 350 kW maximum capacity. And when powered by renewable energy, said the company, these machines offer a CO2 saving of 84% (for the A30 Electric) and 90% (for the A40 Electric) across their entire lifecycle, when compared to their diesel equivalents.
These electric models include advanced operator support systems to reduce accident risk, improved visibility for safer oper-
ation and simplified servicing for quicker and easier maintenance. The integrated Co-Pilot display offers easy control over cameras and machine status, while the dynamic instrument cluster provides key data such as charging status, machine hours and energy consumption.
The electric haulers were among Volvo’s zero-emission-only lineup at bauma. In addition to the electric artics, highlights on display included revamped electric excavators, mobile charging stations, the new EWR150 Electric, the company’s first battery-powered wheeled excavator, and the EW240 Electric Material Handler grid-connected excavator.
6. Expanded zero-emission series
One focus of Wacker Neuson at bauma was the consistent expansion of its zeroemission product portfolio. The company offers a wider range of dumpers, excavators, rollers, telehandlers compactors and wheel loaders. The ultimate goal is to operate an entire construction site without direct exhaust emissions.
One first is the new E-wheel loader WL300e, which expands the portfolio of compact electric wheel loaders. The unit’s built-in 48-V lithium-ion battery is available in three power levels, so that running and charging times can be optimally adapted to work requirements.
The WL300e operates completely exhaust-free and with significantly lower noise emissions versus IC versions. For the user, this means greater flexibility, environmental protection and significant savings in operating costs, according to company officials.
Battery size depends on the application and intended use. Standard maintenancefree battery is 14.1 kWh, and optional 18.7 kWh and 23.4 kWh versions are available. A 3 kW onboard charger is installed as standard. A second 3 kW charger can be added to increase charging power for fast-charging medium and large batteries.
The machine has a 6.5 kW traction electric drive with a max speed of 15 kmh. An 8.5 kW electric motor powers the working hydraulics providing max flow of 36 lpm and 225 bar max pressure. A single steering
VOLVO'S A30, PICTURED, AND A40 ARE THE WORLD'S FIRST SERIAL-PRODUCED BATTERY ELECTRIC ARTICULATED HAULERS, FEATURING 29-TON AND 39-TON PAYLOADS.
cylinder handles the hydraulically activated articulated pendulum steering for an oscillating angle of ±10 degrees.
The machine can be equipped with rear hydraulic connections (single or double-acting). This increases the machine’s range of applications through rear hydraulic attachments or tipper trailers. Thanks to a hydraulic quick-hitch system, attachments like lift forks, mowers, brushes, and snowplows can be readily exchanged.
Lifting arm damping can be activated electrically to enhance safety and comfort for the operator. The feature provides optimum machine handling on rough terrain and when traveling on roads. It's especially useful when moving a loaded bucket or heavy attachment over a long distance at high speeds.
7. Rotating backhoe cab
Backhoe loaders have been best-sellers due to their ability to load and dig with just one machine. Yet switching between these functions can be taxing, especially when performed dozens of times a day. Mecalac's Revo990 is said to revolutionize the operator experience with a rotating cab, eliminating the hassle and providing a seamless changeover.
Since their creation in the 1950s, backhoe loaders are based on a traditional tractor design fitted with a loader arm at the front and an excavator boom at the rear. This means the operator must turn around
to switch from one function to the other, and that forces operators to perform a long sequence of tasks just to turn the seat.
According to Mecalac, the process is slow, interrupting operations and degrading the machine’s fast-cycle capabilities. Operators cannot drive the machine in digging mode: when facing the excavator end, they have no access to the steering wheel and pedals. Further, direct visibility on the tool is hindered when using the boom angled to the side
To address these issues, Mecalac redesigned the architecture to shift the burden from operator to technology. Its innovative design merges the operator and cockpit,
MECALAC'S REVO990 FEATURES A ROTATING CAB, ALLOWING FOR ONE-TOUCH CHANGEOVER FROM THE LOADER ARM IN FRONT AND EXCAVATOR BOOM IN THE REAR.
rotating as one to enhance performance, comfort, and safety.
The Revo990 functions as a high-reach excavator and a powerful loader, seamlessly transitioning between the two functions in just a few seconds, thanks to its one-touch seamless cab rotation. This groundbreaking feature lets operators maintain optimal posture when swinging from one function to the other, significantly minimizing the risk of back and neck strain caused by uncomfortable twisting.
Also, the Revo990 backhoe’s rotating cab offers an unparalleled view of the jobsite and ongoing operations. Unlike traditional solutions with limited two-way visibility, the Revo990 provides almost infinite cab positioning, allowing for clear sightlines in every direction.
For example, while digging trenches, the Revo990 lets operators reposition the machine to continue digging further along the trench without having to stop to turn the seat and switch to loader mode or to push themselves forward awkwardly with the backhoe. All driving controls remain within reach whatever the mode, streamlining movement and eliminating interruptions. It is even possible to maneuver with the cab positioned at a 90-degree angle, making it ideal for tasks alongside roads, such as ditch cleaning. This enhanced visibility lets operators work more efficiently and stay focused on the task at hand. FPW
ANOTHER ELECTRIC OPTION FROM WACKER NEUSON. THE E-WHEEL LOADER WL300E, FEATURES POWERFUL HYDRAULICS FOR STEERING, ATTACHMENTS AND MORE.
Still the Biggest Problem for
Contamination: Fluid
Power Systems
Industrial systems, whether pneumatic or hydraulic, must prevent a variety of contamination sources to run reliably.
By: Josh Cosford, Contributing Editor
FLUID POWER SYSTEMS EXPERIENCE MANY PROBLEMS. Poor designs, inferior quality components, maintenance neglect, severe climate, and operator error can all inflict trouble on your innocent machine. However, most of these problems are rare cases because poorly designed machines with cheap parts lose their market quickly, and modifications can be made to suit your machine’s environment.
So, where does contamination appear in the problem rankings in the fluid power world? Is it still at the top? You bet it is. And let’s be clear that contamination comes in many forms, not just particles. Marriam-Webster (marriam-webster.com) circularly defines contamination as “a process of contaminating.” As far as I’m concerned, dictionaries using the query word in the definition is contamination, but I digress. Digging deeper, they say that to contaminate means “to make unfit for use by the introduction of unwholesome or undesirable elements.”
Using the above definition, how many causes of contamination can you think of in fluid power? There are particles, of course, and they are what comes to mind immediately when most people think of contamination. And because particle contamination is so common, every single compressed air system and hydraulic power unit contains one or more filters. →
AIR FILTERS ARE PLACED THROUGHOUT INDUSTRIAL AUTOMATION SYSTEMS TO PROTECT THE ACTUATORS AND VALVES CONTROLLING THE PROCESSES FROM CONTAMINATION.
Wet air breeds contamination
If you thought this article was only about hydraulics, you just found out you’re incorrect. The pneumatic system professionals already know the second source of contamination, and that is water. Water separators are a common in-line accessory in air lines through any facility, as are air dryers for high-demand shops. Pneumatic valves, actuators and tools are often more resilient from water contamination than hydraulics because they’re designed with suitable materials under the assumption of the presence of water.
Water is in the air that both we and air compressors inhale, and when the compressor takes a cubic foot of air and squishes it down to a tenth of its original volume, water “rains” out and settles in the air lines. Water control in pneumatics is a bigger task than the control of particles. You find a large filter directly after the compressor but also nearly every station in the
COOLERS, LIKE THE TSUNAMI AFTERCOOLER, PRE-COOL COMPRESSED AIR BEFORE IT REACHES DOWNSTREAM EQUIPMENT, MAXIMIZING MOISTURE REMOVAL AND IMPROVING EFFICIENCY.
plant requiring connection to the shop air grid, where FRLs (Filter Regulator Lubricator) are installed. However, the very design and layout of pneumatic plumbing revolves around the control of water.
The first defense in the battle on water is the various devices engineered to remove it before it becomes a nuisance to downstream equipment. Refrigerated, desiccant, membrane, deliquescent, and aftercoolers are all types of drying devices with their own particular benefits and flaws used to remove water. Which one you use will depend on the volume of air your facil-
ity uses and the dryness of air required. Food & beverage, medical and pharmaceutical manufacturers, for example, will use multiple devices especially desiccant dryers, for ultimate dryness. However, refrigerated dryers are the most common because of their flow capacity and reasonable price.
The layout of air system piping is thoughtful of the control and elimination of water. You don't simply run air pipes or tubes to the stations around your plant requiring it, but instead, install the plumbing up high and install drop lines at machines or work areas requiring compressed air. Distribution lines mounted up high take advantage of gravity so condensed water will settle downward. And rather than simply drain through the valves, actuators and tools, downward extensions are installed where small volumes of water can settle. Installing a ball valve or drain at the bottom of the tube or pipe provides a method to drain
the collected water, which should be a task done daily, depending on the efficiency and capacity of your drying equipment.
Wet oil wreaks havoc on hydraulics
If water is bad for pneumatic systems, it’s downright horrific for hydraulics. Water contamination in hydraulic fluid results in corrosion, oxidation, accelerated wear, microbial growth, and in extreme cold, pos-
HEAT EXCHANGERS SERVE AS COOLERS TO REMOVE HEAT FROM SYSTEMS.
DRAG US THROUGH THE DIRT
We Can Handle It
We expect your worst every day. It’s why we engineer and test for it in every one of our high-performance hydraulic hoses. With abrasion resistance second to none you can treat our hose like dirt. As for our team, they’ll treat you like gold. See why we’re the name to know. Make A Continental Shift.
sible freezing damage. Excessive water, especially in its free form, can result in rapid and catastrophic failure as metalto-metal contact under high pressure will shear, shred and sunder even the most durable pump designs.
Prevention is always the best medicine, so provide water no opportunity to enter your reservoirs, power units, actuators or plumbing. It's much more difficult to remove water from hydraulic oil than it is from air, so your efforts are better used with intelligent design that inherently prevents water intrusion. A raised filler cap prevents any potential reservoir-top water from leaking into the breather-filler cap, for example. Better yet, installing a desiccant breather cap also ensures that a highhumidity atmosphere isn't inhaled into the reservoir.
Also, keep in mind that water also exists as humidity within hydraulic oil, just as it does in our atmosphere, and just like our atmosphere, it can "rain" out when the temperature drops. So, in a humid plant or location, your machine may run warm enough to hold a generous amount of saturated water. Be mindful that cooling will induce localized pools of free water. That water will circulate during the subsequent machine startup, offering up the potential for harm.
Once water contamination occurs, you can use water-absorbing filter elements to remove free, circulating water. However, the humid oil requires more effort to dry, and expensive machinery such as vacuum dehydrators might need to make an appearance to avoid replacing all your oil. These machines will heat up the oil under a vacuum, lowering the water's boiling point and then sucking away the humidity.
The dangers of heat
Although less of a popular opinion in fluid power circles, heat is also a form of contamination that damages both pneumatic and hydraulic systems. Pneumatic systems create heat simply by taking atmospheric air and squishing it down to a fraction of its original volume. And if you squish ten cubic feet down to one cubic foot, the total heat energy in that ten cubic foot
“If water is bad for pneumatic systems, it’s downright horrific for hydraulics.”
HYDAC Optimizes Your Machine for Peak Efficiency
HYDAC offers a variety of filter flow capacities and configurations, including duplex and multi-tower arrangements to meet any requirement.
Stat-X element media technology provides electrostatic charging/discharging mitigation, ensuring that your critical system is safe from its harmful effects, such as:
• electronic component failure
• dangerous external discharges
• combustion in the tank
• poor system performance due to:
– varnish/sludge build-up
– oil aging
space now exists concentrated into the smaller volume. The higher your shop air pressure the more heat you create, and there is no way around it.
Heat in compressed air systems can damage seals and O-rings, oxidize lubricants, and degrade the plastics that constitute plenty of pneumatic valves and components. Aftercoolers placed immediately after the compressor will reduce the heat entering the receiver (the storage tank), and sizing your receiver large enough to create dwell time provides a period where heat can radiate away. Otherwise, the long runs of pneumatic plumbing, often made from metals, provide an excellent heat sink that radiates any remaining heat from the compression stage.
In hydraulic systems, excessive heat has the potential to allow total devastation more quickly than any other form of contamination. Hot oil thins out dangerously where it can allow metal-on-metal contact, where pumps, motors, valves and cylinders
3D MODELS NOW AVAILABLE
on the Adaptall Website, 3D Models are available for all part series! e have partnered with CADENAS to help bring you 3D models in all of our part families with over 9500 Models to download in over 100 rent for mats! isit our website for more details!
COALESCING FILTERS REMOVE SOLID PARTICLES IN COMPRESSED AIR.
can all fail prematurely.
A cool hydraulic machine starts with an efficient design, where thoughtful consideration for matching output energy with input energy is made a priority. High-quality pumps such as piston or inside-gear designs are ideal here, and so are versions employing load-sensing or horsepower control technology. Each design wastes little energy while creating closer to the actual pressure and flow demanded by actuators.
Additionally, the creative selection of valves also reduces leakage and, therefore, heat. If you can achieve a function with a poppet valve, do so since spool valves are inherently leaky. Avoid valves with highpressure drop, such as priority-type flow dividers, where fluid is lost as heat before achieving useful work.
If all else fails, a cooler can be added to any machine. Depending on the heat load, your options range from small heat exchangers that mount near the back of
the electric motor to take advantage of the motor’s cooling fan. The most common are simple liquid-to-air coolers that use electric or hydraulic motors to power fans to increase the cooling rate. For ultimate heat removal, liquid-to-liquid coolers can remove hundreds of horsepower of heat, especially if your plant has cooling towers or access to open-loop cooling.
A common problem: particle contamination
This brings us to the form of contamination that gets the least attention in this article because it gets the most attention every other day: particles. The problem with particles is that machines generate them just from daily operations. Although manufactured (built-in) contamination is highest at machine startup, and ingested contamina-
tion can also cause dramatic spikes in circulating nastiness, these can either be anticipated or avoided. Meanwhile, internally generated particle contamination will occur, even at low rates, no matter what is done to prevent it.
Always remember that particles can act like a lapping compound, essentially sanding away at valves, pumps, motors and cylinders, increasing contamination exponentially if your filtration quality is low. There is no such thing as a hydraulic filter that is too fine, and it's been proven that expensive and efficient filters will pay for themselves over time.
No matter the form of contamination, being mindful that they can and will conspire to damage your precious and expensive machines allows you to waylay each type before catastrophe strikes. Keep your machines clean, cool, and dry, and you can sidestep tradition by avoiding what is still the biggest problem for fluid power systems — contamination. FPW
REGISTRATION OPEN For Growing iVT Expo
With more exhibitors and a growing conference platform, the iVT Off-Highway Vehicle Technology Expo promises two educational-filled days August 20-21 in Chicago.
By: Mary C. Gannon, Editor-in-Chief
Registration is now open for iVT Off-Highway Vehicle Technology Expo, taking place on August 20 & 21, at the Donald E. Stephens Convention Center, Chicago. This event, now in its fourth year in the U.S., showcases the latest advancements in off-highway vehicle technology, including hydraulics, motors, sensors, switches, joysticks, robotics, actuators, HMI and more.
More than 150 exhibitors will exhibit at the event, with about one-third of those being fluid power manufacturers, distributors and system integration companies.
Education at the core
The two-day event offers educational sessions, industry updates, live product dem-
onstrations, and networking opportunities with professionals in the off-highway vehicle industry. For the second year in a row, the National Fluid Power Association is producing a conference track.
While NFPA is still developing the program, seven sessions have been confirmed and more will be finalized in the coming weeks. They include the following:
Optimizing Packaged Electrification Systems for Mobile Equipment, presented by Andy Cailteux, Product Management and Business Development and Justin Hernan, Project Engineer, Parker Hannifin. They will explore examples of packaged system solutions for the electrification of mobile equipment, including ePumps and ePTOs, and explore typical component breakdowns. They will also examine how packaged solutions can help to optimize motor sizing,
provide higher efficiencies using variable versus fixed hydraulic pumps, and reduce system noise. Finally, they will also explore smart control solutions and describe how advanced laboratory testing can be a key component of the design process.
Off Highway Power Transmission Methods, presented by DJ O’Konek, Engineering Manager, Nott Company. He will discuss various power transmission designs used to transmit energy from the prime energy source, such as an ICE engine or a battery, to the vehicle location where work is performed, such as work functions or propulsion, in an off-highway system. The talk will examine details of each methodology, explore their benefits and challenges and use case examples. Four methodologies will be explored: an ICE Hydraulic system, an ICE hydraulic/electric hybrid system, a battery electrohydraulic system, and a battery electric system.
Efficiency Improvements in a MiniExcavator Using a Distributed Independent Metering Valve System, presented
by
Aaron Jagoda, Systems Engineer, Danfoss Power Solutions. Conventional hydraulic systems impose efficiency penalties on electrified off-highway equipment, increasing battery costs and reducing run-time. This presentation covers the development and testing of a distributed independent metering valve (dImv) system on a miniexcavator designed to mitigate these losses. Efficiency improvements come from minimizing meter-out losses, leveraging intelligent regeneration and gravity lowering, implementing electronic flow sharing, and eliminating hose burst valves. IMUs enhance load status detection, enabling more efficient control strategies. A comparison to the baseline machine will be presented, with measured efficiency gains of 12–25%, with simulation results showing dIMV’s synergy with multi-pump architectures and energy recuperation strategies.
Unlocking Efficiency in Electrified Hydraulic Systems, presented by Chase Younker, Electronics Product Manager, HAWE Hydraulik. Can batteries replace the combustion engine for hydraulic work func-
Fisher, Director of Engineering Shared Services, Sun Hydraulics. The integration of connected devices in hydraulic systems revolutionizes monitoring, diagnostics, and efficiency. By leveraging an IoT device with analog sensors and monitored cartridge valves, you can continuously track performance, predict failures, and optimize maintenance schedules. This proactive approach enhances uptime, reduces unplanned downtime, and streamlines technical support through remote diagnostics and automated alerts. Data-driven insights improve energy efficiency and system optimization, reducing operational costs.
Hydraulic Data from the Heart of the Circuit: Pump Output Digitization, presented by Mark Preissig, General Manager,
tions? The answer is complex and multifaceted, but a direct swap of engine for battery to run the same old hydraulics is not practical. Hydraulics are unique and favorable in off-highway machinery, but a significant portion of the energy consumed is wasted. But what if current technology could enable a smarter working hydraulic system? Could less battery be used to do the same amount of work? From load-sense systems to active independent metering valves and the help of AI, he’ll explore real solutions for efficiency.
Remote Diagnostics & Support Using Connected Devices, presented by Cory
Casappa Corp. Recent research and development has produced a new on-board data digitization solution for hydraulic pumps. Currently applied to field-proven, variable displacement piston pumps, the system is equipped with embedded electronics and sensor technology, able to measure, utilize and transmit hydraulic performance information. Principles of operation are described, with features such as predictive maintenance calculation, detection of eminent failure through anomalous conditions, analysis of duty cycle severity, and data conditioning and transmission capability supporting cloud-based telematics. Tech-
IVT EXPO OFFERS A GROWING EXHIBITION AND SEVERAL CONFERENCE TRACKS TO HIGHLIGHT THE FUTURE OF OFFHIGHWAY MACHINERY.
FARM STRONG. FLUID SMART.
Looking for a cost-effective solution to enhance your hydraulic or fluid system? Our Diaphragm Accumulator delivers reliable energy storage, shock absorption, and pulsation dampening—ensuring smoother operations and extended equipment life. Maximize efficiency without breaking the budget!
nology in contamination sensing and fluid condition monitoring will be previewed.
Fully Digital Electro-Hydraulic Systems: Integrating Real-Time Control, AIEnabled Safety, and MISRA-C Compliance, presented by Michael B. Terzo, P.E., Founder and CEO, Xirro LLC; Director and Board Member, HeavyTech Inc. Terzo explores the transformative integration of digital electro-hydraulic systems in off-highway applications with real-time operating systems and advanced AI-driven safety features that adhere to rigorous MISRA-C standards while also meeting stringent defense certification requirements. He will illustrate how the convergence of digital sensors, smart actuators, and deterministic control architectures not only enhances efficiency and reliability but also fulfills the high-security standards demanded by defense applications.
Although not part of the NFPA Conference, Danfoss will also present an additional talk on the iVT Conference side. Recharging the future: Charging infrastructure for high-powered machines, presented by Sam Jones, Application Engineer, Editron/ Danfoss. This presentation explores grid connection options available globally, highlighting their roles in the adoption of electrified machines and vehicles. It delves into the contrasting charging methods, comparing dc fast charging and ac charging, and examining their efficiency, speed, and accessibility. Additionally, the presentation discusses the different charging ports used worldwide, emphasizing the importance of standardization and compatibility. It also investigates the integration of multifunctional components in charging infrastructure, focusing on how they enhance the overall functionality and convenience of electric vehicle charging.
Exhibitors prepare for machinery of the future
Fluid power exhibitors will be highlighting innovations for electrified, digital machines well as more traditional technologies.
“Parker Hannifin will showcase the relaunch of Pneumatics Virtual Engineer, a powerful online tool for pneumatic product selection, and the FORCE Command electro-hydraulic actuator built for demanding
“For the first time, Bailey Electronics and Bailey Hydraulics will be unified within a single exhibitor booth, presenting a comprehensive portfolio of high-performance products.”
mobile applications,” said Juanita McGowen, Marketing Communications Manager –Motion Systems & Fluid Connector Group. “Our modular ePTO systems, including the GVM Power Series motor and GVI Gen 2 inverter, that provide high efficiency and easy integration for electric and hybrid vehicles will be on display. Visitors will also learn about Parker’s Steer-by-Wire technology and the new 48V Adaptive ePTO from Parker Chelsea, designed to enhance control and sustainability in work trucks.”
Sam Thompson, Marketing Communications Manager, Webtec Products Ltd., said they will be highlighting their CTA hydraulic flow monitor which now features a 4-20 mA output. “While this device can already monitor and transmit oil flow and temperature data via a J1939 CAN-bus interface, the addition of a 4-20mA (3-wire loop) analog output for flow reporting facilitates easy permanent installation on industrial and on/off-highway machines,” Thompson said.
The new 4-20mA output supports easy integration with existing systems, taking advantage of the M12 connector for the electrical port. It requires less wiring and connections than other signals, for simple configuration.
IC-Fluid Power will be showcasing a full lineup of compact and efficient hydraulic solutions. This includes its IC Series rotary actuators, engineered for high torque in compact spaces. For weight savings, they also offer ultra-lightweight carbon fiber cylinders, up to 80% lighter than conventional steel without the compromise of strength or durability. IC Fluid’s Hytorc series (including butterfly valves, rubber compensators, and high-performance check valves) enhance system efficiency and control.
At the Danfoss booth, the focus will match their presentations on eHydraulics said Lindsay Schleisman, Head of Global Public Relations. The eHydraulic Power Module will be on display, highlighting the benefits of packaged solutions for electric machinery. The eHydraulic system integrates a Danfoss Editron synchronous reluctance assisted permanent magnet motor with a Danfoss variable displacement axial piston pump to maximize performance and efficiency. The compact package also offers mechanical advantages, simple installation, and high reliability. Supplying the electric motor and hydraulic pump as an integrated system eliminates the risk of noise, vibration, and component damage that can arise when using a flexible coupling to join the components. It also simplifies and accelerates installation as there’s no need for the OEM to connect the components.
Bailey International will demonstrate its solutions for industrial and off-highway vehicles, with a focus on advancing efficiency, reliability, and operator comfort, said Brianna Henderson, Marketing Manager. “For the first time, Bailey Electronics and Bailey Hydraulics will be unified within a single exhibitor booth, presenting a comprehensive portfolio of high-performance products. These include precision-engineered joysticks, armrests, ergonomic controls, and advanced hydraulic components, all designed to meet the demands of next-generation work trucks and specialized applications in sectors such as construction, agriculture, and transportation,” Henderson said.
Bosch Rexroth and HydraForce will showcase customized compact hydraulic solutions, including live demonstrations of compact hydraulics products, including Rexroth's compact load-holding valves, HydraForce's EHBL digital boom control valve, new Bosch Rexroth series of EDG-OBE piloted compact directional valves, HydraForce's Oil Condition Sensor in partnership with Tan Delta Systems, its HF-Impulse 2.0 Configuration and Programming Software for HydraForce electronic controllers, and Compact Power Modules for mobile and light industrial applications. FPW
Duplex and in-line pressure filters
Eaton eaton.com/filtration
Expanded high-performance filter series includes the DUA, LWF, and DNR. DUA duplex filters keep filtration running smoothly by allowing the operator to divert the filtration flow from one side to the other. Handling operating pressures up to 320 psi (22 bar) and flow rates of 1,056 gpm (4,000 lpm), they are best for power plants, manufacturing facilities, and marine systems. LWF in-line pressure filters can be installed on suction, pressure, or return lines and are equipped with the pleated 01.E1501 filter element that boosts dirt-holding capacity. This series handles operating pressure up to 232 psi (16 bar), flow rates between 396 gpm (1,500 lpm) to 1,585 gpm (6,000 lpm). DNR duplex pressure filters are suitable for systems that need to withstand operating pressures up to 232 psi (16 bar). Designed with a three-way changeover valve, these filters allow for element changes without halting filtration and are well suited for lubrication of gear boxes and turbines.
Vane pump offers high efficiency, low noise
Parker Hannifin parker.com
T8MINI medium-duty, fixed-displacement vane pump achieves high operational speeds and high service pressure at low displacement. It meets the growing demand for more efficient, low-carbon electrical equipment and is especially suitable for mobile mini and mid-size machinery. Combined with a synchronous brushless electric motor, the T8MINI significantly improves machine performance to deliver high efficiency, high machine operational time, low noise levels and low total cost of ownership — all in a compact footprint. The series is available in four displacement variants – 6, 8, 10, and 12 cc/rev, with speeds up to 5,000 rpm, pressure up to 330 bar, and output flow up to 60 lpm.
Electro-proportional hydraulic cartridge valves
Expanded electro-proportional cartridge valves fit into the compact T-10A cavity. The new RPEP and RPEN valves are rated to maximum pressure to 5,000 psi (350 bar) and have flow capacity up to 25 gpm (95 lpm). The RPEP is suited for industrial machines like a hydraulic press, which requires precise pressure regulation. This 2-port, pilot-operated, electro-proportional pressure regulating valve serves as an effective system relief valve. It electronically controls system pressure by adjusting the analog input signal to the coil. To maintain efficient operation of mobile equipment, the RPEN can be used in fan drives to dynamically control fan speed and ensure temperature regulation. It acts as the relief valve to protect the system from overpressure if the fan motor stalls, and modulates the pressure proportional to a given command to control the fan speed based on the system’s cooling needs.
Volume boosters with expanded temperature capabilities
ControlAir LLC controlair.com
High capacity volume boosters now include an expanded temperature option which broadens the range of industrial environments they can operate. EPDM is now an option that expands the operating temperature range to –65° to 284°F (–54° to 140°C). The Type 6100/6200 High Flow Capacity Volume Boosters are a 1:1 signal to output relay that, when used with a positioner/actuator, are engineered to boost stroking speed in valve actuation systems where high flow and rapid exhaust are critical. An integral bypass valve provides system stability while allowing normal positioner airflow and precise valve actuation during small input changes. The soft valve seat design ensures tight shutoff and eliminates leakage during steady-state operation, reducing costly air consumption. They handle up to 250 psig (17.0 bar) supply air pressure and provide output air pressure of up to 150 psig (10.0 bar).
Sun Hydraulics sunhydraulics.com
Proportional directional valve with electronics for explosive areas
HAWE Hydraulik hawe.com
Manufacturers of mining machinery, oil and gas plants, and chemical plants can now also use the PSL-CAN directional spool valve with onboard electronics in potentially explosive atmospheres. The actuating head has been redesigned to comply with current regulations such as ATEX, IECEx, MA, and CCC. The high repeat accuracy, achieved by a very low hysteresis, is suitable for recurring movements. The CAN actuating head is pressure-proof encapsulated. Up to 10 valve segments in three sizes from the modular system can be combined in one control block. This results in a robust and resistant control block that also controls the individual functions reliably
Compact radial piston motor
Bosch Rexroth boschrexroth.com
Compact, integrated MPR Performance radial piston motor saves around 25% in components and up to 30% in length. It reduces installation space and lowers the machine’s center of gravity. Performance benefits include up to 9% higher start-up efficiency, an optional 470 bar rated pressure, and a 25% higher maximum speed for lower system costs and TCO. Removing need for complex cooling solutions increases productivity, reduces operating costs, and boosts design flexibility for next-generation machinery. As the first radial piston motor at this frame size with axial porting and a lamellar disc brake, it unlocks new vehicle design possibilities. Adaptable shaft configurations streamline variant management, while standardized interfaces ensure easy integration and backward compatibility.
Thermoplastic hydraulic hose for material handling
Danfoss Power Solutions danfoss.com
Synflex by Danfoss 3TMH thermoplastic hydraulic hose is designed for material handling machinery such as telehandlers, boom lifts, scissor lifts, and more. It is 10 times more abrasion resistant than comparable hoses, providing a longer lifespan that maximizes machinery uptime and reduces replacement intervals and associated costs. The hose maintains peak performance throughout 1 million impulse cycles. It is up to 40% more flexible than other thermoplastic hydraulic hoses, and simplifies installation, to reduce assembly time. It is constructed from synthetic rubber or patented Dura-Pulse rubber inner tube, one- or two-wire braided reinforcement, and a thermoplastic polyurethane cover. FPW
Robert Sheaf • Founder of CFC Industrial Training
Cylinder not cycling after pilotoperated directional valve change-out
I WAS ASKED TO TRAVEL TO CALIFORNIA
to troubleshoot a problem with a hydraulic system. This system stroked a cylinder which pushed product into a furnace. The main directional valve was changed due to a porosity hole that started leaking oil only when the valve was shifted. After this valve change-out, it stopped cycling.
The customer was under considerable pressure to get it up and running and felt he had done all that he could. He also did not fully understand the circuit. He claimed the only thing he did was change the valve with a spare they had in stock that looked just like the original. I told him how to check the pilot’s orifice inside the valve to make sure the pilot was getting a signal from the main system supply. He found that blowing shop air into the “X” port resulted in air coming out of the “P” port. This showed it was not blocked with a solid pilot pressure plug.
What would you do next? We welcome responses of all kinds directly to Bob Sheaf at rjsheaf@cfc-solar.com or to mgannon@wtwhmedia.com The solution will be provided in conjunction with our next edition of Fluid Power World and will be published online next month.
Solution to stuttering cylinder can’t maintain rolling mill position
Servo systems are especially sensitive to the compressibility of the oil and stretch of the mechanical system. Replacing a steel tubing line with a flexible hose caused the problem. Hoses expand when pressurized and contract when the pressure drops. Replacing the steel tube with a hose caused a change in the harmonics of the system.
Switching the hose back to the steel tube solved the problem. FPW
Precision Control Solutions
Designing efficient systems involves much more than simply understanding a few basic principles. There is a true art to balancing the specific requirements of an application in order to achieve the desired goals in the best possible way. Help us understand the unique needs of your application and together, we’ll develop something that surpasses what any of us could have done alone.
Contact your distributor to learn more, or visit clippard.com to request a free catalog and capabilities brochure.
