FLUID POWER WORLD FEBRUARY 2022

Hydraulics in the movies p. 16

Electrification in mobile machinery p. 36

Precise control through electropneumatics p. 42

www.fluidpowerworld.com

February 2022

Grippers raise food-processing efficiency, sustainability PAGE 30

Cover FINAL 2-22_FPW.indd 1

2/9/22 1:52 PM

KNOW Pressure Our low-cost pressure sensors gauges make it easy /

Proven Pressure Sensors/Gauges

Starting at $8.25 Get great prices on our vast selection of accurate, dependable pressure sensors and gauges.

• Electronic and mechanical switches · Transmitters and vacuum transducers · Digital switches and transmitters · Digital and dial pressure gauges · Differential pressure gauges and transmitters

NEW! DPTW Series Differential Pressure Transmitters Starting at $795.00 ProSense DPTW differential pressure transmitters are precision engineered for accurate differential or gauge pressure measurement of a wide variety of liquids, gases, and steam.

• Measures differential, positive, or negative pressures • Capable of also measuring hydrostatic liquid level and flow (additional flow elements required) • Up to eight times smaller than a conventional style DP transmitter • Various measuring ranges of up to 400 inches of water column • 12-32 VDC operating voltage with 4-20 mA outputs and ¼-inch female NPT process connections • Rugged NEMA 4X housing

Also Available Digital Pressure Air Differential Switches/Transmitters Pressure Transmitters

Digital Pressure Gauges

Research, price, buy at:

www.automationdirect.com/pressure-sensors www.automationdirect.com/pressure-gauges

Order Today, Ships Fast! * See our Web site for details and restrictions. © Copyright 2021 AutomationDirect, Cumming, GA USA. All rights reserved.

2202-FluidPowerWorld-PressureSensors-MAG.indd 1

1-800-633-0405

the #1 value in automation

1/5/2022 9:05:13 AM

FLUIDLINES Mary C. Gannon • Editor

Getting back to in-person with FPTC 2022 If there’s one thing I’ve always said about fluid power, it’s that I love the people I work with daily, both in my own circle of employment but also within the companies I cover on a regular basis. In 17 years writing about hydraulics and pneumatics, I’ve had many opportunities to travel to conferences, trade shows, customer meetings and reader visits — and even though I am a writer at heart — those personal friendships and connections will forever be my favorite moments.

I think that’s why the past two years have been so difficult for many of us. We’re social beings, and after two years of staying home, Zoom meetings and canceled or virtual conferences and trade shows, I think we’re all itching to get back out there and see each other again. Fluid power is personal; it’s about relationships and not just about powerful machines and the systems that run them.

That’s why I am excited to announce that we’re bringing our Fluid Power

Technology Conference back to in-person programming this year, with two events slated in June and October.

We will kick off the event in Minneapolis/St. Paul, as we co-locate with our sister brand for their DeviceTalks event on June 6 and 7. Here, we are planning to work closely with the engineering faculty from the University of Minnesota to coordinate some sessions and a possible tour of their R&D labs there as well. I can vouch for the innovation you’ll see at UMinn, which is home to the CCEFP as well — on a personal vacation to Minneapolis several years ago, I spent a morning visiting the campus to see the research being conducted there.

We will also be hosting FPTC 2022 at Macomb College in Detroit, October 12-13, with a pre-conference workshop day on October 11. Again, we are working with the faculty there as well to allow attendees to see their hands-on classrooms and labs, where they are educating the future users and designers of fluid power systems.

I am passionate about the FPTC because it is most importantly, an educational event, where we bring some of the industry’s brightest minds together to train and inform the users, maintainers, and

designers of fluid power systems. Attendees can learn about the latest trends and innovations, as well as get some basics on component technologies, troubleshooting, system design, maintenance, and more.

It is events like these, too, where I get a chance to connect with some of my favorite individuals in the fluid power space. Both old and new partnerships with experts such as Carl Dyke, Tom Wanke, Josh Cosford and now, Robert Sheaf, of CFC Industrial Training — give our attendees the knowledge they need.

If you attended any of our FPTC events in the past, our FPTC Virtual Series, or our Engineering Week late last month, you know what type of content will be offered there.

So I invite you to save the dates for one or both of these in-person events and I hope to connect with you there, too, and forge some new fluid power friendships!

FPW

Mary C. Gannon • Editor mgannon@wtwhmedia.com On Twitter @DW_marygannon

POSITION SENSORS FOR HYDRAULIC CYLINDERS  Absolute detection of the cylinder stroke  No piston drilling necessary  Can also be used in telescopic cylinders  High shock and vibration resistance, IP69K

SIKO Products Inc., www.siko-global.com

AXIAL LOAD SUPPORT

RADIAL LOADOVERLOADS SUPPORT RADIAL

RELIABLE. ROBUST. AVAILABLE.

Overhung Load Adaptors • Provides Radial and Axial Load Support • Extends Motor/Pump & System Lifetime • Seals Out Dirt and Contamination • SAE A-F and non-SAE Mount Options • Standard Models / Fully Customizable • Engineering Assistance / Fast Delivery

www.zero-max.com 800.533.1731

Zero-Max OHLA Fluid Power World 2021.indd 1

3/4/21 2:02 PM

FROM THE FIELD Paul J. Heney • VP, Editorial Director

John Deere and the autonomous future

At last month’s Consumer Electronics Show in Las Vegas, John Deere put on an impressive hybrid press conference to announce its fully autonomous tractor.

This isn’t some concept machine or a test vehicle. We’ve seen plenty of those over the years from OEMs; this is one that’s ready for large-scale production. The machine combines Deere’s 8R Tractor, TruSet-enabled chisel plow, GPS guidance system, and new advanced technologies.

The autonomous tractor will be available to farmers later this year.

Presenters focused on the fact that farming is exhausting mentally and physically — and this advance will allow farmers to focus on other things while allowing for better outputs from the farm. Plus, there’s a gap between the labor that is needed on the 4

FLUID POWER WORLD

2 • 2022

farm and the labor that is available. What’s more, farmers need lots of labor for short periods of time … autonomy will help, because a tractor can be out 24 hours a day and run constantly when soil conditions are just right. For example, with seeding, if the optimal planting window is missed, the crop output can go down by as much as 1% with each passing day.

Overall, three main benefits were discussed. First, there’s timeliness.

Autonomous vehicles don’t call in sick or get tired and can run 24 hours per day.

Second, is efficiency. This technology allows farmers to be more efficient because they’re not in the cab all day. They can focus on the whole operation. And third, is about quality of life. The company says it will be improved, as being in a cab up to 18 hours a day is physically and mentally exhausting.

What’s clear is that this technology is making great strides and will be part of all our worlds in the coming years.

Fluid power will continue to be used www.fluidpowerworld.com

for key actuation operations on these types of vehicles — but now’s the time to start asking ourselves how our technology will have to adapt. The greater availability of inexpensive sensors means that components and systems can be connected to the IoT, and functional improvements like predictive maintenance will become expected and not extras. Fluid power can still be a mainstay here, but it’s clear that we must keep innovating, every bit as fast as the other parts of the vehicles our systems are on.

FPW

Paul J. Heney

VP, Editorial Director pheney@wtwhmedia.com

On Twitter @wtwh_paulheney

FEBRUARY 2022

C ontents |

vol 9 no 1

|

fluidpowerworld.com

2

•

2022

F E AT U R E S

INDUSTRIAL AUTOMATION

Innovative grippers raise food-processing efficiency, sustainability Vacuum technology is essential for safely handling food products without damage or waste.

MOBILE HYDRAULICS

Sustainability and electrification top the trends in mobile machinery The rapid rise of climate concerns has sped up various changes in mobile machinery, spurring changing designs in fluid power systems.

PNEUMATICS

Precise control through electropneumatics Electropneumatic flow controllers provide precise control of air flow to actuators, ensuring reliable and consistent speed and motion.

6

•

FLUID POWER WORLD

30 36

42

D E PA R T M E N T S

02 FluidLines 04

From The Field

10

Korane’s Outlook

12

Troubleshooting Challenge

14

Association Watch

16

Design Notes

24 Fundamentals

ON THE COVER

26

Maintenance

28

Energy Efficiency

46

Products

50

Component Focus

52

Ad Index

Special grippers, such as this bell-shaped design, help reduce food waste and increase economical and sustainable production.

SILVER NATIONAL AWARD

SILVER REGIONAL AWARD

asbpe.org

asbpe.org

| courtesy of Schmalz Inc.

2 • 2022

LEAD TIMES OF HOURS INSTEAD OF DAYS OR WEEKS. With today’s logistics challenges and stretched lead times, we’re here for you with our Hydraulex Reman™ line. Remanufactured pumps, motors and valves engineered to deliver OEM level performance and that carry an industry-best 24-month warranty. With our unmatched on-the-shelf inventory of units and parts, and our ability to convert or build units in hours instead of days or weeks, we’re sure to have the unit or part you need right now. Speed and availability redefined.

Put a Hydraulex Reman™ unit to work for you.

1-800-422-4279 sales@hydraulex.com www.hydraulex.com

FEBRUARY 2022 • vol 9 no 1 • www.fluidpowerworld.com

Don’t compromise!

EDITORIAL

MARKETING

PRODUCTION SERVICES

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

VP, Digital Marketing Virginia Goulding vgoulding@wtwhmedia.com @wtwh_virginia

Customer Service Manager Stephanie Hulett shulett@wtwhmedia.com

Editor Mary Gannon mgannon@wtwhmedia.com @dw_marygannon

Digital Marketing Manager Taylor Meade tmeade@wtwhmedia.com @wtwh_taylor

Associate Editor Mike Santora msantora@wtwhmedia.com @dw_mikesantora

Digital Production/ Marketing Designer Samantha King sking@wtwhmedia.com

Senior Editor Ken Korane kkorane@wtwhmedia.com @fpw_kenkorane

Use MAIN Manufacturing Products, Inc. as your source for hydraulic flanges Dependable - 60 yrs service Informed - members of SAE & NFPA tech committees

MAIN Manufacturing Products, Inc.

SAE 4-bolt, JIS, DIN, ISO standard & special adapters

Grand Blanc, MI USA

Socket and Butt weld, NPTF BSPT, ORB, BSPP, 6149, etc.

800.521.7918

In-line, el, tee, F, blind, cross, reducing, flange heads

Quick - Thousands in stock specials can be 3-4 days

Info@MainMfg.com

Made in USA

MAINMfg.com

Materials: Carbon, 304L, 316L, duplex, Cu-NI, ductile, alum. etc.

Contributing Editor Josh Cosford @FluidPowerTips Contributing Editor Carl Dyke @carlindustry Contributing Writer Robert Sheaf rjsheaf@cfc-solar.com PRINT PRODUCTION

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

Marketing Graphic Designer Hannah Bragg hbragg@wtwhmedia.com Webinar Manager Matt Boblett mboblett@wtwhmedia.com

IN-PERSON EVENTS

Webinar Coordinator Halle Kirsh hkirsh@wtwhmedia.com

Events Manager Jen Osborne jkolasky@wtwhmedia.com @wtwh_jen

Webinar Coordinator Kim Dorsey kdorsey@wtwhmedia.com

Event Marketing Specialist Olivia Zemanek ozemanek@wtwhmedia.com

ONLINE DEVELOPMENT & PRODUCTION

Event Marketing Coordinator Alexis Ferenczy aferenczy@wtwhmedia.com

Web Development Manager B. David Miyares dmiyares@wtwhmedia.com @wtwh_webdave

VP, Creative Services Mark Rook mrook@wtwhmedia.com @wtwh_graphics Art Director Matthew Claney mclaney@wtwhmedia.com @wtwh_designer Senior Graphic Designer Allison Washko awashko@wtwhmedia.com @wtwh_allison Graphic Designer Mariel Evans mevans@wtwhmedia.com @wtwh_mariel Director, Audience Development Bruce Sprague bsprague@wtwhmedia.com VIDEO SERVICES Video Manager Bradley Voyten bvoyten@wtwhmedia.com @bv10wtwh Videographer Garrett McCafferty gmccafferty@wtwhmedia.com

FINANCE

Senior Digital Media Manager Patrick Curran pcurran@wtwhmedia.com @wtwhseopatrick Front End Developer Melissa Annand mannand@wtwhmedia.com

Controller Brian Korsberg bkorsberg@wtwhmedia.com Accounts Receivable Specialist Jamila Milton jmilton@wtwhmedia.com SALES

Software Engineer David Bozentka dbozentka@wtwhmedia.com

Ryan Ashdown 216-316-6691 rashdown@wtwhmedia.com

Digital Production Manager Reggie Hall rhall@wtwhmedia.com Digital Production Specialist Nicole Lender nlender@wtwhmedia.com Digital Production Specialist Elise Ondak eondak@wtwhmedia.com Digital Production Specialist Nicole Johnson njohnson@wtwhmedia.com VP, Strategic Initiatives Jay Hopper jhopper@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 @jpowers_media Courtney Nagle 440.523.1685 cseel@wtwhmedia.com @wtwh_CSeel

www.nfpa.com

WTWH Media, LLC 1111 Superior Ave., Suite 2600, Cleveland, OH 44114 Ph: 888.543.2447

•

Fax: 888.543.2447

2011- 2020

2014- 2016

2014 Winner

2013- 2017

FLUID POWER WORLD does not pass judgment on subjects of controversy nor enter into dispute with or between any individuals or organizations. FLUID POWER WORLD is also an independent forum for the expression of opinions relevant to industry issues. Letters to the editor and by-lined articles express the views of the author and not necessarily of the publisher or the publication. Every effort is made to provide accurate information; however, publisher assumes no responsibility for accuracy of submitted advertising and editorial information. Non-commissioned articles and news releases cannot be acknowledged. Unsolicited materials cannot be returned nor will this organization assume responsibility for their care.

FLUID POWER WORLD does not endorse any products, programs or services of advertisers or editorial contributors. Copyright© 2022 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.

SUBSCRIPTION RATES: Free and controlled circulation to qualified subscribers. Non-qualified persons may subscribe at the following rates: U.S. and possessions: 1 year: $125; 2 years: $200; 3 years: $275; Canadian and foreign, 1 year: $195; only US funds are accepted. Single copies $15 each. Subscriptions are prepaid, and check or money orders only.

SUBSCRIBER SERVICES: To order a subscription please visit our web site at www.fluidpowerworld.com FLUID POWER WORLD (ISSN 2375-3641) is published seven times a year: in February, April, June, July, August, October, and December by WTWH Media, LLC; 1111 Superior Ave., Suite 2600, Cleveland, Ohio 44114. Periodicals postage paid at Cleveland, OH & additional mailing offices.

POSTMASTER: Send address changes to: Fluid Power World, 1111 Superior Ave., Suite 2600, Cleveland, OH 44114

8

FLUID POWER WORLD

2 • 2022

Since 1986, GRH has manufactured hydraulic components such as gear pumps, orbital motors, power packs, sectional valves, and mono-blocks.

ALA Industries Limited

3410 Delta Dr • Portage, IN 46368 Tel: 877-419-8536 Fax: 219-762-2066 Web: www.alaindustrieslimited.com

KORANE’S OUTLOOK Ken Korane • Contributing Editor

Hydraulics takes a direct hit Up until now, mobile electrification efforts were a shot across the bow of the hydraulics industry. Doosan Bobcat just hit it broadside.

At this year’s CES 2022 in Las Vegas, the company premiered a new all-electric Bobcat T7X compact track loader, said to be the first machine of its kind to be fully electric and which completely eliminates the hydraulic system.

“Doosan Bobcat is at the forefront of innovation, and we are proud to debut the allelectric technology of the T7X to help customers maximize both sustainability and productivity,” said CEO Scott Park.

In terms of sustainability, that may be true, particularly if the electricity comes from renewable sources, not coalburning power plants. With zero emissions it will undoubtedly run cleaner and quieter than a diesel counterpart. This type of compact off-road equipment is well-suited for operations where municipal regulations prohibit diesel

machines; where noise or exhaust are an issue, say in congested urban settings; and for indoor work where it could reduce or eliminate manual labor.

The traditional hydraulic work group has been completely replaced with an electrical drive system consisting of electric ballscrew actuators and electric drive motors. The electric systems are more efficient than conventional hydraulics and should reduce maintenance costs. And they may offer finer control and smoother motion, and simplify condition monitoring.

In terms of productivity, however, the jury is still out.

Bobcat claims the T7X provides high-performance torque and more power than similar dieselfueled track loaders. But a 62 kW lithium-ion battery powers electric actuation and propulsion.

As industry expert Joe Kovach of KoMotion Technologies noted during WTWH Media’s

Engineering Week roundtable on mobile electrification, the energy content of a gallon of diesel is about 38 kW. You don’t have to be a math major to understand why, with a low energy density, the T7X can only work continuously for about four hours, at best. And for the same operating capacity, it weighs 20% more than similar standard machines.

Then there’s compliance.

In hydraulics, the fluid acts like an elastic spring. That opens the opportunity to dampen oscillations that are transmitted to the cab. Electrics don’t offer this benefit. “Compliance is a great thing to have,” said Kovach.

Otherwise, working in the field, digging and hitting rocks sends tremendous shock loads through the system to the detriment of operator comfort and safety.

Ball screws have additional issues, he continued. They are not jam tolerant and most are not easily back-drivable, which

All-electric Bobcat T7X compact track loader

means you can’t recover energy.

Hydraulics can build in energy recovery, say when lowering a large load. Ball screws also have to take extreme measures to protect against dirt and contamination or else they quickly wear out. And when they’re run at low speeds, reliability and life are concerns.

And then there’s cost.

Batteries are still quite expensive, and inverters and electric motors aren’t cheap. Some companies indicate that right now, building a comparable electric machine costs two to three times more than a diesel model. And mobile manufacturers don’t have the luxury of high production volumes to drive down price, as in the automotive industry. Today, OEMs are accepting the reality that electric vehicles are more expensive, and are focused on efficiency and less maintenance in hopes of lowering total operating costs over the long term.

Many people want to go all-electric in principle. “But to just jump on the electrification bandwagon and put batteries on all construction equipment is kind of naive. There isn’t one size that fits all,” said Kovach.

To gain widespread acceptance, electrics need a breakthrough in battery technology. And hydraulics needs to raise the bar on efficiency, building on new developments like floatingcup and digital-displacement pumps, and low-loss internal gear designs. Hybrid electrichydraulic systems could offer the best of both worlds, to the ultimate benefit of customers and the environment.

FPW

10

FLUID POWER WORLD

2 • 2022

www.fluidpowerworld.com

In-line or manifold mounted filters for high pressure circuits are used as working filters with the task of protecting a single valve or the entire hydraulic circuit from fluid contamination in compliance with international ISO 4406 standards. Six (6) versions are available with working pressures that range from 1595 to 8120 PSI.

PASSION TO PERFORM

www.mpfiltriusa.com (215) 529-1300 sales@mpfiltriusa.com

TROUBLESHOOTING CHALLENGE Robert Sheaf • Founder/CEO of CFC Industrial Training

Introducing Troubleshooting Challenge Fluid Power World is happy to introduce a new column to our audience — Robert Sheaf’s Troubleshooting Challenge. Many readers may be familiar with these puzzling fluid power problems, as Sheaf has been penning his challenges for decades in several industry publications.

Each month, Sheaf will highlight a situation where he was called to consult on a malfunctioning system or machine, provide a circuit to highlight the machine’s functions and ask you, the reader, to troubleshoot the problem.

Readers are encouraged to engage with Sheaf to discuss the problem. The answers will be printed in the following issue of Fluid Power World.

Sheaf founded Certified Fluid Consultants (CFC) in 1990 and is owner/CEO of CFC-Solar, Inc. (currently operating as CFC Industrial Training). He has been directly involved with fluid power for 45 years and has taught fluid power courses for 39 years throughout the United States, Canada and Mexico.

Sheaf has been actively involved for more than 32 years with the International Fluid Power Society (IFPS), having served in several leadership roles including president, director on the Board of Directors, chairman of the Certification Board and past president of FPS Publications.

He holds several IFPS certifications and other certifications for training and working offshore oil & gas rigs.

Rod gland keeps failing on a large bore cylinder 14" B X 7" ROD X 48" LONG

A new hydraulic system was installed and commissioned with very little problems. However, after

PLATEN

10,000#

about four weeks the rod gland failed on the cylinder. Inspection showed the threads were stripped on the bronze gland. The customer insisted that the distributor supply a new cylinder which they did, but the new cylinder also failed after six

EM

weeks of operation.

12

FLUID POWER WORLD

2 • 2022

The circuit attached had a 45-gpm pressure-compensated pump driven by a 100 hp, 1,800 rpm electric motor. The compensator on the piston pump was confirmed to be set at 3,000 psi and the cylinder was rated for 3,400 psi operating pressure.

Can you identify what was the problem? We welcome responses of all kinds directly to Robert Sheaf at rjsheaf@cfc-solar.com or to mgannon@wtwhmedia.com. The solution will be provided in our April 2022 issue.

FPW

www.fluidpowerworld.com

Congratulates

HAPPY ANNIVERSARY, YATES CYLINDERS!

For over 50+ Years Yates continues to set the bar for quality Hydraulic and pneumatic cylinders. World class customer service and cutting-edge technology. Yates has the capabilities to manufacture and repair all your custom cylinder needs from NFPA tie-rid, welded type, and mill duty. Equipped with one of the largest and most complete repair facilities in the Mid-West United States, complete with 4 locations, 330,000 sq. ft. of manufacturing space, in-house engineering, CNC machining, welding, assembly, and testing, there is no job Yates can’t handle.

www.yatesind.com

Yates Anniversary ad 2-22_FPW.indd 13

2/11/22 2:07 PM

ASSOCIATION WATCH Edited by Mary Gannon • Editor

IFPS highlights technical workshop at Spring Meeting The International Fluid Power Society will host its annual Spring Meeting at the Embassy Suites Historic Charleston, March 7-10, in Charleston, South Carolina. The event offers committee members a chance to get together for future planning activities.

Committees include strategic planning, education, membership, certification, marketing and finance. In addition to these committee meetings and social networking opportunities, the event will host a technical workshop from 8 a.m. to 2 p.m. on Monday, March 7.

open circuit proportional work function control requirements for today’s off-road mobile equipment including:

The workshop will be on “Proportional Directional Control Valves for Mobile Hydraulic Applications,” presented by Randall Bobbitt, CFPAI, Danfoss Power Solutions. It will include an extensive tour of

•

• • • • •

Proportional spool valve design basics Comparison of industrial versus mobile work function control requirements Variable pump vs fixed-pump system considerations Open circuit load sensing systems Deep dive into pre-compensated versus post-compensated work function control Latest development trends for open circuit work function control.

Visit ifps.org/technical-workshop-2 for information and to register.

Nominations open for Hall of Fame

ESA scholarship applications are open

The Fluid Power Hall of Fame was established to

The Equipment Service Association sponsors a

acknowledge those individuals who have dedicated their

scholarship program each year, with a limited number of

careers and have made significant contributions to fluid power

scholarships awarded to ESA members, families, employees,

technology. Innovators, researchers, application engineers,

and employees’ families who meet the criteria. Winners will be

educators, and sales and service personnel are the reasons our

selected at random in an open drawing of all qualified applicants

industry continues to thrive.

during the ESA Annual Convention. Applicants do not need to be

Any person can nominate an individual, living or deceased, who demonstrated excellence within their 25-plus year fluid power career — one nomination per category (living or deceased) per person.

The following requirements must be met for nominations: • •

Those nominated are asked to complete an application (unless a posthumous nomination).

Verifiable 25-plus cumulative years in the fluid power industry.

present to win.

Three $2,000 ESA scholarships will be awarded this year to students in all fields of study.

Applicants must be sponsored by a current ESA member and must be enrolled in an accredited college, university or trade school, or taking at least six credit hours in the Fall 2022 semester. Applicants must have a 2.5 gpa and must complete the application to the Scholarship Committee no later than April 30.

A panel of judges will review applications and select inductees.

The inductees will be announced on June 19 – Fluid Power Professionals Day. Inductees will be honored during the IFPS awards dinner being held in October, in San Diego.

Visit fluidpowerhalloffame. org to nominate an individual.

Nominations will be accepted until April 15.

FPW

14

FPW

FLUID POWER WORLD

2 • 2022

www.fluidpowerworld.com

Visit 2esa.org/scholarships for more information.

FPW

NFPA members connect with university students through fluid power clubs

IFPS releases New Fluid Conveyance Guide Information provided in the new Fluid

Conveyance Guide can be found in a variety of other

NFPA has been renewing applications and signing up new schools to support Fluid Power Clubs on university campuses. The goal of this initiative is to get younger students introduced to and interested in fluid power, support club activities, and connect students to industry professionals to learn about careers in fluid power.

So far, these universities have active clubs on their campuses this year: 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

Iowa State University Milwaukee School of Engineering Murray State University North Carolina A&T State University Northern Illinois University Ohio University Purdue Northwest Purdue University South Dakota State University University of Alabama at Birmingham University of Cincinnati West Virginia University Institute of Technology Western Michigan University

but with this guide, readers have access to easily searchable information all in one place.

The guide includes: • •

•

•

NFPA supports clubs at universities to help students learn about fluid power while they work on educational and technical projects. Students can participate in the NFPA Vehicle Challenge, gain access to speakers and mentors in the industry, learn about job opportunities in the industry and gain leadership experience and professional development.

Requirements for clubs include: • Must be four-year college or university • Must offer Bachelor of Science (BS) degrees • At least three student members (one must beat or below junior level) • Faculty advisor who oversees fluid power club activities.

NFPA is still accepting applications. If you know of a university in your community that would benefit from up to $2,000 in stipend funding, industry access, and other resources, they can apply at nfpa.com.

To get engaged with any of these universities, contact Stephanie Scaccianoce sscaccianoce@nfpa.com.

FPW

publications

• • •

Reference tables for both ISO and SAE Hose Specifications Information for pressure ratings of pipe, tubing and hose to assist in the proper selection for the fluid being used: hydraulic or pneumatic Information to help in selecting the right size of fluid conductor utilized to ensure the best efficiency by minimizing pressure losses Information to assist in determining the correct fastener to use and how to identify the different types of fasteners and their applicable sizing standards — i.e., BSP, NPT, JIS, DIN, GAZ Information for sizing Code 61 and Code 62 Flanges split and one-piece Standard O-ring sizing chart Information on bending and flaring tube assemblies and the use of the tools required

The guide is available to members for $19.95.

Non-member, retail price is $38.95. Purchase includes print and online access. The printed guide is permitted to be used during a Certification test. Online access only is also available.

Visit ifps.org/training-materials to order.

www.fluidpowerworld.com

2 • 2022

FPW

FLUID POWER WORLD

15

DESIGN NOTES Edited by Mary C. Gannon • Editor

Hydraulic sensing brings special effects to life in the movies Draw-wire encoders are not the kind of component that is normally associated with motion picture production. But draw-wire encoders from SIKO GmbH were used for ensuring precise and safe control in compact spaces in “Fantastic Beasts” and “Midnight Sky.”

The carriage drawn by

so-called Thestrals in ‘Fantastic Beasts 2’ uses SIKO draw-wire encoders for rotational movements.

16

FLUID POWER WORLD

2 • 2022

SIKO draw-wire encoders are used by the British company Absolute MoCo, which develops and builds hydraulic studio environments for special effects in movie productions. Together with his partner David Watkins, Special Effects Supervisor at Absolute Effects, Andy Ryan wanted to be able to create movements for special effects in the movie industry that are more accurate and more authentic. For him, the technical effects available in the UK for this purpose were outdated. The aim of Absolute MoCo is to enable people to move more precisely and safely in film scenes. “We specialize in creating the conditions for motion control of certain motion sequences in movies with moving base platforms and in sets. We act as a link between VFX and the physical world and have developed a reliable HMI and software package for movie production. For some filming we still use open loop systems, but we mainly prefer systems with a closed control circuit to guarantee www.fluidpowerworld.com

positioning and reliability, which are crucial in movie production today. Using absolute encoders from SIKO gives us the opportunity to repeat takes as often as we like. This means that we can work safely, stop safely and identify positions at any time. This technology has catapulted the physical side of special effects to a new level and is getting better all the time.”

Wire-actuated encoders integrated into the hydraulic cylinder

Hydraulic movements are a particular challenge if they are to appear natural and still be safe to perform physically.

Various SIKO draw-wire encoders are used to determine the position of the hydraulic cylinders. All the encoder types have in common a design that is both robust and compact, making them suitable for the smallest spaces.

The SGH10 draw-wire encoder, which was used, for example, in scenes for the Warner Brothers production “Fantastic Beasts: The Crimes of Grindelwald,” has a distinctive, patented feature: it is integrated directly into the hydraulic cylinder and measures the position — i.e. the extension of the cylinder — directly. The advantages: the integrated design means that the draw-wire encoder is protected from external factors. There is also no need to drill out the piston to accommodate the draw-wire encoder, as is the case with other solutions such as those with magnetostrictive sensors. An additional

Precise and authentic movements

are ensured in the 12-meter boat deck in “Fantastic Beasts,” thanks to SIKO draw-wire encoders in the hydraulic cylinder.

work step of this kind is also a cost factor, which is avoided by using integrated draw-wire encoders.

Detection of position and speed During a rescue scene in which a fully occupied boat had to be tossed to and fro as authentically as possible on the high seas, three movement axes were involved that had to be hydraulically driven (Trio Motion Technology), plus a rotational movement as a fourth, which was enabled by the integrated SIKO draw-wire encoder. “This enabled us to create a line from the visual effects to the Maya special effects platform and to perform the movement in any direction while staying within the viewing angle of the camera,” Ryan said. “A further advantage of the SGH10 is evident in dynamic applications such as this, where multiple cylinders on the platform

must be moved synchronously: In addition to position, the draw-wire encoder can also measure speed, so allowing the cylinders to be extended at the same speed and to run in parallel.”

Safe movement sequences

The SGH10 integrated drawwire encoder was also used in the special effects for the movie “Midnight Sky.” In the communications room of the spaceship, the leading character Sully must move on a chair both sideways and vertically to various control buttons; the chair was positioned on a hydraulic cylinder fitted with the integrated SGH10 measurement system, which determined the height and travel speed. This ensured the safety of the actor, and the movement was smooth. Since the space on the floor below the chair was very restricted, the encoder type integrated into the cylinder

The compact SG10 (orange), SGH10 and SG20 draw-wire encoders from SIKO.

was chosen as the best solution.

“Space restrictions are the rule rather than the exception in our projects,” confirmed Ryan, “and so we often turn to SIKO’s compact draw-wire encoders. Our team also appreciates the variety of the measurements, as the encoders can detect both linear and rotational movements. This opens up a wide range of applications.”

Externally mounted draw-wire encoders

As well as sensor types integrated into the cylinder, SIKO also offers externally mounted sensors, which are also used by Absolute MoCo in particular situations.

These include the SG 10 and SG 20 (highly compact external drawwire encoders with a maximum measurement length of 2,000 mm). If, say, the base structure is already in place, these draw-wire encoders can be retrofitted. This considerably reduces the effort and outlay for construction. For Ryan, an important factor in complex hydraulic ramps is the option to replace sensors. “If a mechanical problem occurs and the sensor perhaps fails, it is significantly easier to replace an external draw-wire encoder than to have to dismantle the entire ramp to replace a sensor that is integrated into the cylinder. The time saving is crucial here,” he said. In these situations, the team prefers a solution with external encoders.

including integration of SIKO drawwire encoders. The highest priority is the safety of all functions.

Including the draw-wire encoders, either integrated or external, is straightforward, and this is also the case at the commissioning stage.

“We have a separate movement control system with different interfaces and were delighted that the draw-wire encoders were ready to operate straight away, even with our own interface. You just connect them and off you go,” Ryan said.

“The manuals and accompanying documentation from SIKO are also very helpful.”

Absolute MoCo is currently involved until Christmas in producing a movie for Marvel Studios. “This time we will try to push the boundaries with our hydraulic effects,” Ryan emphasized.

“And of course, we’ll be using SIKO draw-wire encoders again.”

FPW

SIKO GmbH | siko-global.com

Filming for “Murder

on the Orient Express” also used wire-actuated encoders from SIKO.

Easy to integrate

Absolute MoCo does not build the cylinders itself, but rather has them constructed by a supplier to its own specifications and designs, www.fluidpowerworld.com

2 • 2022

FLUID POWER WORLD

17

DESIGN NOTES Edited by Mary C. Gannon • Editor

Supplier expertise helps make hydraulic test stand vision a reality

The system used JIC fittings,

various tees and inline check valves to keep the pressure from going backward. Hoses on the design included two wirebraided hoses rated for 5,000 psi and 4 wire spiral hose in high impulse application.

Collaboration is key between customers and their manufacturers and distributors, as a recent custom build from Power Drives Inc., a manufacturer and distributor specializing in industrial fluid transference and filtration, shows.

18

FLUID POWER WORLD

2 • 2022

A long-term customer of the Tonawanda, N.Y. PDI Express Hose Center had come in with a new project to tackle: A hydraulic snowplow cylinder testing stand. The customer manufactures rod and telescopic cylinders, engineering them to customer designs.

The stand was to be designed to test the functionality of the snowplow cylinders. www.fluidpowerworld.com

Snow plows handle thousands of pounds of snow, so they had to test the cylinders for motion under such pressure. They also had to test for the “break away:” Snowplow cylinders use two single-acting cylinders so once a certain pressure threshold is reached, the cylinder will break away, activating the locking mechanism to retreat to the rest position. This is a very important safety

check for snowplows because poor visibility can lead to hitting curbs or other objects under the snow. The test stand had to be designed to test multiple cylinders, multiple strokes, and extend and retreat up to 18 in. under 3,000 psi.

On a project of this magnitude, it was important that the customer worked with a supplier they had a long-standing relationship with and whom they trusted. They had worked with PDI on various projects in the past, benefiting from the company’s expertise and product recommendations.

While the customer was in the process of designing the machine, they came into the store with a plan on a piece of paper, with the specifications they were looking for. Sitting down and building hoses piece by piece, the PDI team created hydraulic and pneumatic fluid transference solutions for the entire system. Fittings, check valves, hoses and tubing were all created and chosen collaboratively in the store. The fittings are a combination of high-pressure steel fittings, and black iron for the plumbing on the low pressure suction side.

The system used JIC fittings, various tees and inline check valves to keep the pressure from going backward. Hoses on the design included two wire-braided hoses rated for 5,000 psi and 4-wire spiral hose in high impulse application.

The customer’s main goal in choosing these products was component and system longevity, which PDI was able to ensure.

Filtration solutions were also addressed and incorporated into the stand, ensuring proper operation and fewer breakdowns and increased equipment longevity.

Since completing and implementing the stand, the customer has seen their productivity in testing increase significantly. For locking cylinders, the ability to test has increased from 17 per hour to 32 per hour. For the non-locking cylinders, testing has increased from 50 to 110 per hour.

When a customer needed a test

stand to test its snowplow cylinders, PDI collaborated with them to design a system that about doubled its testing capacity from 17 to 32 for locking cylinders and 50 to 110 for non-locking cylinders per hour.

FOR SALE

FPW

Profitable Fluid Power Training Buisness

Power Drives Inc. | powerdrives.com

(owner retiring)

• • • • •

2 • 2022

FLUID POWER WORLD

19

Sale Price $125,000 Manufacturing Hydraulic Training Equipment Providing Training and Component Sales Could be operated from any geographical location $75,000 Inventory $200,000 Annual GP

Inquiries: fluidpower12345@gmail.com Website: FluidPowerTraining.com

DESIGN NOTES Edited by Mary C. Gannon • Editor

Terzo’s Hydrapulse units, above and below, are

highly customizable and the company routinely works with OEMs to develop custom connectors, firmware, housings and mounts for specific applications.

Efficient mobile electrification with smart electrohydraulic pump Nearly a year ago, Terzo Power Systems officially launched its electrohydraulic pump systems designed for on- and off-highway mobile vehicles and industrial applications.

Terzo Power Systems developed the world’s first compact and energy efficient smart hydraulic solutions for the electrification of fluid power. Their flagship product, the Hydrapulse, is a complete electrohydraulic system that is a fully integrated power-on-demand hydraulic power unit with built-in intelligence. The energy efficient system, with an electronically controlled motor and pump assembly, are all contained in a small, compact footprint.

Terzo Power Systems is the brainchild of Michael Terzo, a mechanical engineer who graduated from Montana State University and launched the company in 2014 with one goal in mind — to bring a new level of simple, compact, and energy efficient technology to the market. The Hydrapulse is not a traditional hydraulic system but a fully integrated product.

Hydrapulse enables the electrification of fluid power systems such as steering, coolant pumps,

20

FLUID POWER WORLD

2 • 2022

www.fluidpowerworld.com

The software-controlled Hydrapulse

introduces an entirely new level of control for the mining industry without the complexity, lead time, maintenance problems, troubleshooting and cost of traditional hydraulic control valves.

air compressors, hydraulic power units and auxiliary systems in industrial, truck, mobile and much more. Terzo Power System engineers consult with OEMs and manufacturers every step of the way to support their system applications to help them become fluent and knowledgeable in electrification of fluid power. The Hydrapulse’s plug-and-play system is fully customizable and can be installed with minor design adjustments configured easily and independently from manufacturer settings.

Terzo has been working with mining manufacturers to simplify their machines. “Since our product is perfectly suited for electrification and hybridization, our customers in the mining sector are OEMs that are launching either a BEV or HEV vehicle platform to address emissions,” Terzo said.

“This is primarily driven by the need for diesel emission reduction in underground mines where air circulation is critical and reduction of diesel emissions directly impacts the costs of operation on the air systems.

“The vehicles that are being developed with our system include rock drills, shovels, loaders, and trucks for underground,” he said. “Typically, these are specialized vehicles for the mining sector but we are also working with OEMs on their earth moving vehicles that can operate in mining and construction.”

Terzo said that the HydraPulse technology is the only fully integrated hydraulic system on the market that can be powered directly off the high voltage dc bus either from the battery system or the hybrid-electric system.

Any hydraulic work function on a mine vehicle that needs to be powered off a high voltage dc bus or electric engine-generator system is highly suited to the HydraPulse. “We can provide almost any power level of hydraulics needed for vehicles in the 300-hp range and below. We typically work with the vehicle OEM to integrate our system into their vehicles at the system level,” Terzo said.

“This ensures we can provide a hydraulic system that is typically well over 70 or 80% more efficient than a traditional hydraulic system.”

When converting a vehicle over from traditional fluid power architecture to Terzo’s advanced power-on-demand type of system, Terzo said it can easily work with vehicles that are typically below 500 kw of power and below.

“We bring extreme energy savings to any hydraulic system which is a big deal for any electric or hybrid platform but many times the improvement in troubleshooting, maintenance, or controls can be the driving factor. For instance, we can remove over 90% of the components typically seen on a hydraulic system which will improve the size (75% smaller), weight (80% lighter), and complexity of a mining vehicle or machine and significantly help with troubleshooting, serviceability, and controllability,” Terzo concluded.

FPW

Terzo Power Systems | terzopower.com

2 • 2022

FLUID POWER WORLD

21

ONSITE TRAINING

AND CERTIFICATION FOR: Hydraulic Techs & Engineers Electrical Techs & Engineers Pneumatic Techs & Engineers Multicraft Techs & Engineers

UPSKILL YOUR WORKFORCE! CFC provides direct, Industry and/or Machine-specific training to companies the world over.

Our Hands-On Training Equipment is mobilized directly to your facility with Certified Instructors traveling on-site.

This turnkey approach includes all books, materials, equipment, and travel arrangements.

We have the capability to upskill your entire workforce NOW! CFCINDUSTRIALTRAINING.com 7042 Fairfield Business Drive Fairfield, Ohio 45014 +1 513.874.3225 info@cfcindustrialtraining.com

DESIGN NOTES

By Ken Korane • Associate Editor

Doosan Bobcat unveils world’s first all-electric compact loader Doosan Bobcat has introduced its new, all-electric Bobcat T7X compact track loader at the CES 2022 show in Las Vegas. The T7X is said to be the first machine of its kind to be fully electric and, according to company officials, offers the benefits of eliminating hydraulic systems, emissions and vibrations while providing cleaner, quieter machines.

“This machine is a technological feat for Bobcat and for the entire industry,” said Joel Honeyman, vice president of global innovation at Doosan Bobcat. ”We challenged the status quo to deliver a connected, all-electric machine designed for power and performance that previously was not possible.”

Engineers decided to totally eliminate hydraulics on the new T7X for a couple key reasons, said Justin Odegaard, acceleration manager, Doosan Bobcat North America.

“First, a hydraulic system has a lot of connections and components.

For every connection point present in a system, there is a chance that the owner will have a potential leak point. Eliminating hydraulics means eliminating the risk of leaks, and therefore, eliminating the potential for downtime.

“Second, going to an all-electric platform is a lot more efficient than a battery pack running a hydraulic system. This gives us longer operating times without the need for a larger battery, thereby increasing productivity and efficiency over the life of the machine.”

The T7X relies on a 460-V electrical system which best optimizes performance and componentry, he said. “This voltage also yielded the 22

FLUID POWER WORLD

2 • 2022

efficiency we were looking for in terms of overall design.” At the machine’s core is a construction-grade, 62 kW lithium-ion battery from Green Machine Equipment that powers the loader’s track system and all workgroup functions. The charge can support daily work operations for up to four hours of continuous run time and a normal, full day of operation during intermittent use.

The traditional hydraulic work group has been completely replaced with an electrical drive system consisting of electric ball-screw actuators and electric drive motors. Doosan Bobcat collaborated with Moog Inc., a worldwide developer of motion control components and systems, to speed the pace of R&D for electronic-control capabilities of the T7X. Early on, ruggedness and life were specific considerations when building out the machine, said Odegaard. “The actuators are extremely durable devices used in harsh industrial applications. When we couple the

The all-electric Bobcat T7X compact track loader is said to

be the first machine of its kind to fully eliminate all hydraulics. | Courtesy of Doosan Bobcat

www.fluidpowerworld.com

force and position control of the actuators the system can then ensure design parameters are kept in check to ensure the durability exceeds customer expectations as it compares to a traditional hydraulic system,” he said.

According to Moog officials, most centralized systems on a construction vehicle today have one motor and pump distributing hydraulic fluid; the pump is always running. With a traditional loader, the machine would waste energy on every axis for lifting, tilting, moving — even when the machine is stationary.

Moog designed a more efficient system using distributed control to send power only when and where it is required, such as for lifting dirt or moving side to side, and thus wastes little to no energy. The sophisticated power-management system is programmed to sense when loads are increasing, automatically backing off power when not needed to preserve the total energy use and extend the machine’s run time.

Hydraulic Live Swivels Inline & 90°

Moog’s system also efficiently manages motion and heat for the T7X, which keeps each component operating at the right temperature range and reduces energy use.

And the system’s software learns to optimize movements and operations as the T7X works.

Smoothing out the peak moments of energy use can boost run time by more than 25%.

Structurally, only slight design modifications were necessary, due to small size differences between electric and hydraulic components. But for the most part, the T7X looks very similar to conventional machines.

“The T7X has the same frame size as our T76 compact track loader, but it’s new from the ground up. It’s built with about half the number of components found in a diesel-powered, hydraulic-driven loader,” said Odegaard.

The T7X is also said to provide highperformance torque and more power than similar diesel-fueled track loaders.

“Regarding power and performance, the T7X’s breakout forces were found to be more impressive than that of traditional loaders during testing. Not to mention, the machine offers low-noise operations and, because it does not emit exhaust, makes it a great choice for enclosed jobsites.

“Fluid power is an efficient way to convert energy to motion, since it’s dense and cost effective. An electric actuator is one step beyond this intermediate technology, and Bobcat has developed a software platform that takes advantage of the performance and efficiency of an all-electric system. Pushing that technology to give the customer the very best machine was our objective,” he said.

The new unit uses only one quart of eco-friendly coolant compared to 57 gallons of fluid in its diesel/hydraulic equivalent model.

It can also significantly lower daily operating costs, when considering the reduction in annual maintenance costs and elimination of diesel, engine oil, diesel exhaust fluid and hydraulic parts.

“The T7X loader will be in a premium configuration and is priced at approximately three times that of a nicely equipped T76 loader. The T7X loader will cost nearly 90% less to operate than a T76 loader when comparing

all input costs for fuel/electricity and routine maintenance items. Additionally, planned downtime is considerably less because there are almost no planned maintenance items for the T7X,” said Odegaard.

To accompany the T7X, Bobcat will also introduce the world’s first all-electric attachments designed for specific tasks. The first to be developed include an electricallypowered auger to dig holes, an angle broom to sweep clean and a material-handling grapple.

While the new T7X is eco-designed, it is also a smart machine featuring software connectivity via two-way telematics communications. The platform provides integral data about equipment performance, along with operator-focused data to change machine preferences, tune the performance to certain job situations and upgrade product features. This includes variable drive speed at full torque and other features not possible with a diesel-hydraulic machine.

Doosan Bobcat has also announced a strategic partnership with South Carolinabased Sunbelt Rentals, a leading rental equipment company in North America with more than 1,025 locations. Through this partnership, Sunbelt Rentals committed to a significant investment in a large fleet of Bobcat T7X all-electric compact track loaders and electric compact excavators, which will be co-branded and made available in 2022.

Sunbelt Rentals will be the first national equipment rental company to adopt Bobcat’s battery-electric technology and make it available to customers, supporting the environmental, social and governance (ESG) focus for both companies.

Available In BSPP

Switch ® Your Swivel® Switch Your Swivel

Heavy Duty Ball Bearing Design

Simplified hose configuration, less hose and adapters combine to reduce repairs and downtime, cutting the overall cost of hydraulics.

No Kinks No Hose Twisting Full Flow

• Also In 304 & 440 Stainless Steel • Rated To 10,000 P.S.I. • Heat Treated • Custom Design & Sizes Available • Rebuildable Ball Bearing Design • Full Flow —Low Pressure Drop • Superior Quality Alloy Steel • Side Load Resistant

FPW

Doosan Bobcat | bobcat.com

Quality Products Made In The U.S.A. Patent No. 5547233 Fax: 1-763-784-7423 Email: sales@superswivels.com 2 • 2022

FLUID POWER WORLD

23

1-763-784-5531 www.SuperSwivels.com

FUNDAMENTALS

By Josh Cosford • Contributing Editor

Why you should avoid NPT fittings No matter how malevolent, some objects of desire seem to allure us despite our righteous awareness – diesel engines, plastic bags, Tik Tok. Indeed, we like to think that we always choose what’s best for our conscience when offered a choice, assuming we have one. Unfortunately, sometimes we indulge in the contrary and label our decision a guilty pleasure. Netflix binges, ice cream and Animal Crossing, are all benign, for the most part, but will be detrimental when taken to the extreme.

Just as in real life, there are undying habits in fluid power that really need euthanization. Suction filters, “flow makes it go,” and, you guessed it, NPT threads all need to go. I’ve written various articles lecturing you on the pitfalls of the first two mistakes, yet only briefly touched on the dangers of National Pipe Taper threads.

Your death clock ticks, NPT. Shots fired.

American National Standard Pipe Thread is the technical standard for what we colloquially refer to as “pipe threads,” and there are many types, of which not all are tapered. It’s not the only pipe thread, and if you’re reading this from North America, you may be surprised by the worldwide popularity of BSPT, or British Standard Pipe

Taper threads. Also called Rc, this version differs mainly from NPT by flank angle and pitch. I’ll save you the headache – only ¾ in. threads will interchange reasonably.

Regardless, this missive is an attack on all tapered pipe threads, but I’ll be stick to referencing NPT only from here on out.

A history of useful design

Polymer technology did not exist in the middle of the nineteenth century when the NPT thread system was created (only a couple of decades after the British standard), so any method of sealing plumbing was to occur without a soft seal.

The tapered thread design was actually quite creative, as previous plumbing systems used inferior sealing methods, such as oakum, which is a tar-soaked cord stuffed between plumbing joints. At least NPT was a positive seal capable of withstanding what was once considered high pressure.

The secret sauce is in the taper, of course. The taper’s geometry is 1/16 in. in diameter per inch, meaning that when the OD is measured at the tip of the thread, it will be 1/16 in. reduced compared to down the flank. A sixteenth doesn’t sound like much, especially when you consider the taper is only 1/64 in. over a quarter inch.

However, when we’re discussing a solid with defined dimensions forced into space

Which fitting is best?

Tapered thread fittings 24

FLUID POWER WORLD

2 • 2022

Parallel thread fittings www.fluidpowerworld.com

already occupied by a solid with larger dimensions, it takes little for those solids to seal together tightly.

Threads, in general, excel at providing a mechanical advantage much like a lever or pully. The mechanical advantage we calculate by dividing the screw diameter by its pitch. For example, 1/4-8 course thread has a mechanical advantage of 6.3, meaning that for every in.-lb of torque applied, we create 6.3 in.-lb at the screw. When you combine the taper with the mechanical advantage, downright huge forces compress and deform the flanks of the thread, essentially locking each piece to the other (assumed they’re never again divorced).

So yeah, it’s easy to understand why NPT became so popular. But many previously popular trends, even those once purposeful, simply have no place in today’s world. For example, the telephone booth was once necessary, enabling family, friends, and businesspersons to connect to others across town or around the world. Today, phone booths remain more a novelty than an object of use, and amid a pandemic, are nothing more than a COVID-19 transmission site.

Sharing is not always caring.

Why are NPT threads inferior today?

The problem with NPT is that it still works, for the most part. And assuming they do, why am I beefing on them? Listen, phone booths still work, and I don’t see you lining up to call your mom. There are just so many superior sealing methods that all the tapered thread pitfalls make it obsolete. So what are those pitfalls?

While still useful, NPT fittings or pipe threads, should no longer be used in fluid power applications because better designs exist for leak-tight, contamination-free sealing.

As previously discussed, NPT threads seal across their flanks, and as fitting gets torqued tightly, the threads deform and close any clearances to seal tightly. Because NPT seals against the flanks, their peaks and troughs flatten to reduce friction when tightened.

However, friction across the flanks remains high and requires a form of lubrication to prevent galling and allow maximum torque.

The NPT thread lubrication takes the form of plumber’s tape, although sometimes a semi-liquid putty is used, albeit less popular in fluid power. The slippery tape (often revered as Teflon tape) allows the fitting to torque completely rather than hang up due to friction. The tape also fills gaps and imperfections, improving sealing, especially under high pressure.

And herein lies the first reason to avoid using NPT fittings.

Teflon tape or similar products are considered a form of contamination, despite their demand as thread sealants. Thread tape is not contamination in the same vein as dirt or metal particles but still should not find itself voyaging through your hydraulic system.

The best-case scenario results in thread sealant ground between threads and then parturition into the hydraulic system as harmless particles eventually trapped in downstream filters. The worstcase scenario sees chunks of tape plug orifices critical to machine performance, or if you’re incredibly unlucky, the flapper nozzles of your servovalve. Not only is downtime costly, but so too is servovalve repair.

The lack of training with tapered fittings results in more difficulties than contamination.

Technicians or millwrights often apply too much tape wound too many times around the male thread. Rather than filling the

Non-positive sealing always provides the potential for leakage

Teflon tape makes a good, leak-tight seal in NPT fittings, but the tape can introduce contamination and if not wound properly, can reduce proper sealing as well.

space between thread flanks, it results in the entire tape winding “unthreading” and essentially hiking up as the fitting tightens.

Such examples are all-to-common and leave no advantage the thread sealant was supposed to offer.

Don’t even get me started on technicians who feel the need to rethread tape on the fitting before each re-installation … without first removing the first layer!

Even without thread tape, it’s likely you could get tapered fittings to seal with enough torque and thread deformation. And that deformation elucidates the second problem with NPT fittings — you get just one shot at NPT fittings.

Any time you remove an NPT fitting, you reduce its capacity to seal again, even with the addition of tape. Thread flanks do not heal after deformation, and the only solution is to increase installation torque to engage the more unspoiled thread.

Excessive tightening results in detrimental effects of its own, and extreme attempts at resealing NPT fittings may result in catastrophic failure. In fact, NPT threads are prone to cracking when overtightened, and no amount of

Teflon tape will fix a cracked female boss. If you’re lucky, such a crack occurs in a simple adapter.

Repair expense rises exponentially if you crack the port of a valve or component. In our current pandemic era, the real costs come from downtime, where suppliers have been throwing around lead times in scores of weeks.

Better design with other options

Even when all stars align and you’ve got a solid, leak-free connection from your tapered fittings, plumbing multiple fittings and components in a reasonable layout may be difficult or impossible. Inline valves and components may employ three or more ports on varying planes of the body, making it challenging to join more than two components in a circuit. Such cases do require lengths of tubing or hose.

There is always a better way, of course. Eschewing NPT for fittings employing polymer sealing technology ameliorates the headaches above while allowing infinite changes in plumbing with no increase in leaks or contamination. O-ring boss ports, which come in the SAE, Metric or BSPP styles, use threads for

www.fluidpowerworld.com

torque only and use synthetic rubber O-rings to seal. The soft seal technology crushes between the fitting nut and the housing, preventing any fluid from escaping.

Plumbing is more effortless when combined with free-moving nuts on the hose or tube, such as JIC and O-Ring face female ends.

The metal-to-metal sealing surface of JIC works well most of the time but is itself prone to leakage over time. The future of sealing lies with soft-sealing technology, and the current king of plumbing is the O-Ring face. An annular fitting-side groove houses an O-Ring which gets crushed by the flat face of the hose end and sealed effectively after the nut is tightened.

The seal itself does not enjoy immortality, and even should you need to change a hose after many years of use, the replacement O-Ring is an expensive bit of insurance for many more years of leak-free operation. Indeed, it’s those leaks or the potential for them that makes NPT threads something to be avoided. I’ll concede that other industries still enjoy practical tapered fittings, but our hydraulic realm deserves much better, so it’s best to avoid them.

2 • 2022

FPW

FLUID POWER WORLD

25

MAINTENANCE Mary Gannon • Editor

Carl Dyke tests oil samples for particulate contamination.

Why do hydraulic systems fail?

In our recent Engineering Week, I sat down with Carl Dyke, founder of LunchBox Sessions and CD Industrial, to talk about hydraulic system troubleshooting.

In this multi-part series based on that conversation, we’re going to look at why hydraulic systems fail, how system maintainers can prevent failures, and tips and tricks to troubleshoot problems and failures easily.

Before beginning to troubleshoot a machine, Dyke said it’s critical to understand why machines fail in the first place. Is it just time and wear and tear? Do specific components fail more commonly than others?

There are a variety of reasons, he said, but one of the key reasons hydraulic 26

FLUID POWER WORLD

2 • 2022

systems fail is misuse. “Sometimes people are expecting that hydraulic system to do things that the engineers and designers just didn’t intend for it. And when you push things a little too hard beyond the design parameters, something’s got to give. A system is always going to find its weakest link,” he said. “It’s amazing how creative humans can be at pushing the envelope. Probably in a lot of cases that I’m mentioning, it would probably be a mobile machine, but it can happen to a machine in a stationary or factory environment as well.”

Failure to care for the machine is a huge misstep in the industry as well. “Hydraulic machines are robust so it’s easy to just start operating, then forget that they need somebody to give it some tender, loving care at times and look after some of its needs from the maintenance side,” Dyke said.

Perhaps one of the most typical failures www.fluidpowerworld.com

comes with hydraulic valves that get stuck, Dyke indicated. “They get stuck on the inside. That can include a pump controller.

A lot of pumps these days have a very sophisticated controller bolted on, which is typically some type of valving, and they get stuck,” he said. “And somebody must figure out where is that internal sticking.”

Additionally, another key issue comes when settings change. This can be caused because of too many overheating cycles that happened along the way. Or perhaps the system operator or a maintenance technician experimented a little bit and adjusted something. In some cases, vibration may have turned an adjustment screw, and so things have come loose. These little things mean users and maintainers may be unaware that an adjustable setting on the machine may have changed.

Obviously, said Dyke, the biggest issues come from unwelcome contaminants — hard particles and water — that get inside the system. “It’s amazing how often little bits of water, especially in a system that’s not being run continuously, can cause things to go wrong.”

Finally, a common issue especially with today’s systems is that wires can fall off, Dyke said. Most hydraulic systems today

have electronic or electrical elements connected to it, and those wires can disconnect and fall off.

Dyke said it’s difficult to get to the point of the problem in hydraulic systems because it’s rarely obvious from the outside. Visual indications of failure or a problem within the system could include fluid leakage or a color change in the system. “In some cases, if the component has changed color, you may have a problem with your pump, for example,” he said. “What we find in our travel is that just about every color of paint can eventually become black, it seems. But it’s almost like toasting a marshmallow. The first color along the way will be nice golden brown and then eventually black. And so, yeah, if you get to brown or black when your paint color was blue or white or green or something else, then you have an obvious clue from the outside.

“But so many little subtle things can go wrong in a hydraulic system, and there’s no easy clue from the outside as to where the cause is.

You can see where the symptom is, some problem with motion or force or what have you, but where the cause is — that can be over a pretty wide roadmap of locations,” Dyke concluded.

To help users recognize common faults, Dyke listed a few issues that can occur on the production side of a machine that will indicate a problem.

“One of the first ones that everybody reports is some kind of a problem with speed. The machine isn’t keeping up. The hydraulic cylinders are slower at getting their job done. The hydraulic motors are slower,” he said. “We tend to notice that the production line has slowed down, or if it’s

2 • 2022

FLUID POWER WORLD

27

a mobile machine, that it won’t do its job as quickly as it did before.”

Secondly, lack of power or force is a common symptom that something is wrong. “The machine won’t lift as much as it used to. It won’t dig in the hard dirt. If it’s a press, it’s not squeezing the product in the plant the way it used to,” Dyke described. “And then, of course, you’re looking for a pressure issue usually at that point.”

Next, look for systems that don’t run smoothly or are difficult to control. And finally, pay attention to hydraulic system overheating.

In next month’s issue, look for a continuation of this discussion, as Dyke delves into some easy tips to follow to help diagnose your system problems.

FPW

llers ontroan c p tc pum and parts thainants. s e v l Va many contam have due to seize

ENERGY EFFICIENCY Ron Marshall • Contributing Editor

Why should you measure compressed air?

Portable electronic measuring instruments have been indispensable in capturing compressed air system baselines

This shows a sample compressed air profile with pressure gradients, flow and power. This is used by an auditor to assess how well the compressed air system is meeting the needs of the customer.

over the past number of years. Rarely are there enough permanent instruments installed at a typical industrial plant to use to get a clear picture of how well the compressors and dryers are operating. Very often, all a compressed air auditor finds when reviewing system instrumentation is analog pressure instruments and various readings that are made available on the air compressor and dryer control panels.

Getting a complete and thorough picture of a compressed air operating profile requires time-based measurements — taken at a high enough frequency — to capture a true representation of important system variables. These readings typically include: • •

• • •

28

Pressure readings at various points in the system to assess pressure gradients and the state of the system pressure control.

Power measurements of the compressors and air dryers (sometimes derived from amp readings) to assess how efficiently compressed air equipment is meeting the needs of the plant — and to calculate the cost of system operation.

Flow measurements to be used in relating the observed pressure and power to the actual flow demanded by the plant.

Dew point of the compressed air as it exits the air dryer, to determine if the production meets the requested quality.

Temperature of the ambient environment, as very often excess heat is the cause of compressed air reliability and air quality problems.

FLUID POWER WORLD

2 • 2022

The instruments are placed on all significant compressed air system compressors (and sometimes air dryers) and a baseline operating profile is captured, showing how the relevant variables in a system change with time within a measurement period.

The measurement period is selected so that it captures all the possible variations in the facility demand profile, often taken over a seven-day period or some repeating duration (sometimes a month).

Once the sampling period is over, the auditor usually downloads the captured data stream and plots it for viewing. The data is typically analyzed with all the relevant variables displayed on the same time base. This is a very powerful way to assess how compressed air systems are operating. Each parameter is compared and assessed by an experienced auditor and viewed in relation to the system as a whole; this analysis of the data often finds various common problems.

An example of common findings is as per the attached graphic. We can see that the pressure in this facility is highly variable, during some of the measurement period the pressure is too high, causing the compressors to consume more power www.fluidpowerworld.com

than desired. And at higher than needed pressure, all unregulated compressed air demand will consume more flow, causing additional power consumption as the compressors adjust to feed this extra “artificial demand.”

Further to this, by examining the pressure profile, an auditor might find low pressure events that may cause problems with production machinery. Very often, the plant compressor operators have no idea that these events are happening because they don’t have adequate permanent instrumentation installed.

If flow and compressor power are captured by data logging equipment, the reviewer can see what is causing the anomalies. These could be caused by demand exceeding the capacity of the compressors, excessive pressure drops across components and piping, or even problems with the compressor control.

Because adequate data is available, it is a simple exercise to determine the cause.

And once the cause is known, a plan for improvement can be made.

Be sure to have your system measured to ensure your compressed air system is meeting your needs.

FPW

FOR YOUR MOST DEMANDING APPLICATIONS TRUST YUKEN WHERE OTHERS HAVE FAILED, WHERE OTHERS FEAR TO GO, OR WILL NOT GO. BE IT IN • • • • • •

WIND POWER INJECTION MOLDING LUMBER MILLS STAMPING PRESSES GEOPHYSICS SHIPPING

UNEXCELLED IN SPEED AND LIFE

YOU CAN TRUST YUKEN PROPORTIONAL VALVES, LINEAR SERVO VALVES AND SERVO-CONTROLLED SYSTEMS. ALA INDUSTRIES LIMITED 3410 Delta Dr • Portage, IN 46368 Tel: 877-419-8536 Fax: 219-762-2066 www.alaindustrieslimited.com

I N D U S T R I A L

A U T O M A T I O N

Innovative grippers raise foodprocessing efficiency, sustainability VACUUM TECHNOLOGY IS ESSENTIAL FOR SAFELY HANDLING FOOD PRODUCTS WITHOUT DAMAGE OR WASTE. JUSTIN KATZ • MANAGER, VACUUM AUTOMATION COMPONENTS GROUP • SCHMALZ INC. • RALEIGH, N.C.

30

FLUID POWER WORLD

2 • 2022

www.fluidpowerworld.com

THE BELL-SHAPED SPG PRALINE GRIPPER, DESIGNED FOR USE WITH PICKER ROBOTS, IS DESIGNED FOR HIGHLY DYNAMIC HANDLING AND PACKING OF CHOCOLATES REGARDLESS OF SHAPE. | COURTESY OF J. SCHMALZ GMBH

The world wastes about 1.4 billion

tons of food every year, according to the United Nations Food and Agriculture Organization. The United States alone annually discards nearly 40 million tons of food, more than any other country. That’s estimated to be 30 to 40% of the entire U.S. food supply, says the USDA. The food processing industry accounts for a sizeable share of the loss, because products are damaged or contaminated during production, transfer, handling and packaging. Even though more than half of this food would still have been edible, instead, it mostly ends up in landfills and contributes to food insecurity, global warming, and lost profits for manufacturers and distributors.

Schmalz Inc., a supplier of vacuum and handling products and systems and related technologies, is at the forefront of addressing these issues. Its goal is to create innovative solutions that make food-production and packaging processes more efficient, but also more sustainable.

www.fluidpowerworld.com

2 • 2022

FLUID POWER WORLD

31

I N D U S T R I A L

A U T O M A T I O N

THE OFG GRIPPER HAS SLIM AND NARROW FINGERS TO EFFICIENTLY GRASP AND TRANSFER FOOD PRODUCTS WITH VARYING SHAPES. IT IS ALSO USED IN LOGISTICS AND AUTOMATED SYSTEMS FOR PICKING AND PACKAGING SMALL PARTS.

Finger grippers

Vacuum technology has become an indispensable part of today’s food industry, and Schmalz engineers and designers have developed a number of products that help meet customers’ demands for topnotch quality and faster throughput, and facilitate high-speed automation. These include grippers that are FDA-compliant and specifically designed to prevent damage and contamination when sorting, separating or transferring products.

One example is the OFG finger gripper, which the company introduced about a year ago. It consists of four silicone fingers that open with vacuum and close with pressure.

The orientation of the fingers is variably aligned so that centric or parallel gripping is possible both inwards and outwards. And opening angle, gripping force and finger positions can be flexibly adjusted. The compact base body, made of aluminum or PET-P (hygienic-design version), has a flange for ready connection to common robots.

The unit is also available as a combination gripper with a central bellows suction cup for increased gripping force and stabilization during transfer. In this case, a second pneumatic connection supplies the suction cup and controls suction and blow off.

The gentle and low-marking gripper is 32

FLUID POWER WORLD

2 • 2022

suited for a wide range of tasks thanks to a rounded design based on the human hand.

Finger grippers can be used for direct contact with food, such as when transferring products into trays or for quality control. The slim and narrow finger design allows small products to be placed close together, for example for packing a sushi lunch box. And it efficiently FLOW GRIPPERS LIKE THE SFG ARE ENGINEERED TO HANDLE DELICATE, DRY AND POROUS FOODSTUFFS. THEY’RE WELL SUITED FOR USE WITH BAKED GOODS SUCH AS COOKIES, WAFERS AND WAFFLES.

www.fluidpowerworld.com

grasps and transfers organic products with varying shapes and characteristics, such as chicken legs, apples and donuts. Given the universal design, it is also used in logistics for picking and packaging small, irregular parts; and in automated systems that process a variety of different products.

OFG’s flexible fingers with hardness 70 Shore A are about 96 mm (3.8 in.) long, conform to FDA and BfR (German Federal Institute for Risk Assessment) guidelines and are available in high visibility blue. Operating pressure is from -0.8 to 1.0 bar (-11.6 to 14.5 psi), operating temperature range is from -30° to 80° C (-22° to 176° F) and the units are rated protection class IP 68. Lift capacity is up to 1 kg.

Flow grippers for food products

When applications involve delicate food products with minimal surface pressure, users should consider Schmalz Food Grippers, SFG. An SFG flow gripper, equipped with the appropriate suction cup, handles dry baked goods such as cookies, wafers and waffles without damage. That’s despite their highly textured surfaces and, often, a high degree of leakage.

The modular unit generates high suction

ACE Motion & Vibration Control when performance matters ROUND BELLOWS FG-X SUCTION PAD RELIABLY GRIPS AND TRANSFERS EGGS OF DIFFERENT SIZES.

power and only a low vacuum — to ensure the whole cookie ends up in the packaging.

Its soft and flexible lip seals when gripping and effectively dampens and cushions when depositing delicate food products on surfaces.

The gripper features integrated compressed-air vacuum generation and an exhaust duct that controls the direction of outflow air. An optional adapter allows for mounting to horizontal surfaces and standard robot flanges, and the compact and lightweight design (108 gm) and high suction capacity permits highly dynamic processes.

Gripping elements are made of FDAcompliant silicone materials for direct contact with dry food products. Maintenance personnel can easily remove the suction cups without tools, for high system availability. And the hygienic design ensures easy cleaning.

Operating pressure is from 1 to 5 bar (14.5 to 72.5 psi) with suction rates from 270 lpm to 650 lpm (9.5 to 22.9 cfm). For these units, suction and lift capacity vary with volume flow, operating pressure, and the working area of the vacuum cup. For example, static holding force with a 40 mm diameter cup and 1 bar operating pressure (measured on an airtight workpiece) is 3 N (0.67 lbf); with an operating pressure of 5 bar and a 60 mm suction cup, holding force is 34 N (7.6 lbf).

Operating temperature range is from 5° to 75° C (41° to 167° F).

Chocolate suction cups

The bell-shaped SPG suction cup picks up confectionery products gently and precisely — regardless of whether they are round, square www.fluidpowerworld.com

or oval. It’s designed for high-speed handling and packing of chocolates in combination with delta picker robots.

The SPG, made of FDA-compliant silicone, handles round chocolates with maximum diameter of 35 mm (1.4 in.) and oval/ square chocolates with maximum diagonal measurement of 30 mm (1.2 in.).

The suction cup has an extremely thin, soft sealing lip and tapered cup geometry.

This enables efficient picking regardless of shape, and it also optimally grips candies with decorative toppings like almond slivers, hazelnut brittle or coffee beans. At the same time, its large opening allows a high flow rate which compensates for any leakage that these structured surfaces or irregular shapes may cause.

Suction area (diameter) is 33 mm, and the suction force and operating vacuum are dependent on the geometry and surface characteristics of the chocolate. Recommended maximum operating vacuum is-150 mbar so as not to damage the workpiece.

A one-piece, insertable connector element with male or female threads lets technicians quickly change out the suction cup. The male version has an integrated O-ring seal.

Egg handling

Industrial shock absorbers Industrial gas springs Vibration isolation Buy Online Standard products available

Tools Sizing & specification ▪ Online calculations & product selection ▪ Chat function for application assistance

Resources Online & downloadable ▪ ACE CAD database ▪ ACETips video tutorials ▪ Technical blog & case studies

Another specialty from Schmalz is the round bellows suction pad FG-X family of products.

A steep, conical sealing lip reliably grips eggs of different sizes. It’s used for the handling of eggs in packing and sorting machines, and is also suitable for use in breeding stations.

2 • 2022

FLUID POWER WORLD

33

800-521-3320 www.acecontrols.com

I N D U S T R I A L

A U T O M A T I O N

INNOVATIVE AIR-POWERED GRIPPERS ENSURE SAFE AND DAMAGE-FREE TRANSPORT OF DELICATE GOODS.

The cone-shaped bellows ensures maximum stroke immediately after contact with the food and then compresses completely within each other. This increases the lateral stability when transporting eggs from a conveyor belt into the carton.

The cups are available in diameters from 30 to 35 mm and bellows with 1.5 to 3.5 folds. Materials include natural rubber and FDA-approved silicone in a hardness range from Shore A 30 to 50.

Even though the egg gripper is considered a unique item in the Schmalz range, it is actually frequently requested and used. This speaks for our technology concepts, which ensure safe and damage-free transport of even sensitive goods.

Avoiding contamination

Schmalz pursues three goals when developing its suction cups for foodstuffs. They must not damage the goods when they are picked up, moved or placed down. The handling processes must be highly dynamic and efficient, and the grippers must meet the current hygiene regulations in terms of design and material. These are specified by the FDA and the EU. Materials that have direct contact with food must not release any ingredients into it, or only in concentrations that are harmless to humans. Schmalz complies with the stricter FDA specifications and relies exclusively on silicone, which does not 34

FLUID POWER WORLD

2 • 2022

contaminate food thanks to its temperature and chemical resistance.

Depending on the application, additives expand the function. The SI-MD (metal detectable) version, for example, features detectable silicone: A small amount of metal oxide causes metal detectors to alert if the suction cup or part of a suction cup gets into the tray or food. Its blue coloration is also striking, making it more visible to cameras and humans. This is one way to prevent food contamination.

The SI-HD (heavy duty) material is a particularly wear-resistant silicone. The white food-compliant SI-HD suction cups handle highly abrasive goods and have up to twice the service life of normal silicone suction cups.

Topography considerations

In addition to the material, design also plays an important role. Grippers are built to handle sensitive workpieces in many different industries, from the electrical industry to solar cell production. Unlike printed circuit boards or wafers, however, food can leave residues on the suction cups. It must therefore be possible to remove these as quickly and easily as possible.

Hygienic design includes all design measures that make components and systems suitable for cleaning. For instance, consider the OFG finger gripper. The base www.fluidpowerworld.com

body of the unit is made of thermoplastic PET-P (polyethylene terephthalate) and horizontal surfaces, fingers and sealing rings are made of silicone and the screws are made of stainless steel. Additionally, the gripper is compatible with existing Clean-In-Place (CIP) or Clean-Out-of-Place (COP) processes.

The pneumatic connection is also hygienically designed. All connection points such as screw connections, where metal meets metal, are sealed smoothly with sealing elements on the outside. This prevents microorganisms from settling when handling foods such as raw meats and cheese. Thus, hygienic design is another key to preventing food losses in production. If grippers are easy to clean, manufacturers minimize the risk of contaminating the products with bacteria or particles. Hygienic design also offers other economic and ecological advantages: faster and easier cleaning requires less water and cleaning agents and equates to shorter downtimes.

With both our special grippers and universal gripping systems, Schmalz supports its customers in resource-saving management, can aid in the reduction of avoidable food waste, and contributes to economical and, at the same time, sustainable production.

FPW

Schmalz Inc. schmalz.com

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

M O B I L E

H Y D R A U L I C S

SUSTAINABILITY A N D E L EC T R I F I C A T I O N T O P T H E T R E N DS I N M O B I L E M AC H I N E RY THE RAPID RISE O F C L I M AT E C O N CERNS HAS SPE VA R I O U S C H A N G D UP ES IN MOBILE M A C H I N E R Y, S P U R CHANGING DESI RING GNS IN FLUID PO W E R SYST E M S .

A S TA F F R E P O R T

36

FLUID POWER WORLD

2 • 2022

www.fluidpowerworld.com

AS

manufacturers work to eliminate emissions, the first thing to go is often the internal combustion engine. And many believe that out with the engine goes the hydraulics, but that’s not always the case. While the hype might be all-electric machines (as seen on

page 22 with our story about Bobcat’s all-electric loader), these designs can’t fully compete with the lifecycles and power provided by hydraulics, as Ken Korane points out in his column on page 10.

A better option is to increase hydraulic efficiency with optimized fluid power technologies that can work alongside and with electric motor-driven machines instead. Here, we take a look at some mobile machinery and fluid power redesigns that do just that.

THE COMMON PRESSURE RAIL HYBRID SYSTEM REDUCES HYDRAULIC ENERGY LOSSES AND RECOVERS AND STORES ENERGY IN BANKS OF ACCUMULATORS. | COURTESY OF VOLVO CE www.fluidpowerworld.com

2 • 2022

FLUID POWER WORLD

37

M O B I L E

H Y D R A U L I C S

Electrohydraulic system wins Volvo Technology Award

As reported last fall, in the ongoing effort to improve hydraulic efficiency in excavators, the Common Pressure Rail Hybrid system

by Volvo Construction Equipment (Volvo CE) is an innovation designed to improve performance while reducing CO2 emissions, in line with Volvo Group’s net zero carbon ambitions by 2040.

The Common Pressure Rail Hybrid system reduces hydraulic energy losses and recovers and stores energy in banks of accumulators.

A Volvo CE team from Sweden and South Korea worked closely with Finnish company Norrhydro in the research project, leveraging an idea initially born out of academic collaborations. Today, the innovation has matured into a real-world system with ongoing customer trials in the field and it is expected to accelerate the introduction of e-mobility across Volvo CE’s larger excavator platform. The company anticipates the new technology to be available in the excavator market in the near future.

“This innovation enables Volvo CE to offer its customers a truly unique electrohydraulic solution, pushing fuel efficiency to new levels. It’s demonstrating the passion of our engineers to bring forward customer-oriented solutions and systems that will drive the transformation towards net-zero emissions operations. Also, it’s again an example of our strength working in partnerships and achieving amazing results,” said Lars Stenqvist, CTO Volvo Group.

The innovation is designed to reduce energy losses in hydraulics. In the new architecture, all the machine’s work functions are connected to a hydraulic 38

FLUID POWER WORLD

2 • 2022

energy storage system via a common pressure rail, comprised of two or more pressure lines. The energy storage, which consists of hydraulic accumulators, enables energy-efficient recovery of kinetic energy and peak power supply.

For cylinder-driven functions, so-called “smart actuators” are used to achieve energyefficient conversion from hydraulic power to a variable force and speed. The system also allows energy recovery and performance increase of the machine’s rotating loads, such as the swing function through the introduction of variable hydraulic devices.

Thanks to greatly reduced energy losses and the power contribution from hydraulic accumulators, a smaller power source can be used and the need for cooling is reduced.

With higher available power, cycle times can be shortened, for example when loading a truck, which contributes to both efficiency increases and cost benefits for the customer.

The Volvo Technology Award is a mark of recognition for outstanding technical advances that contribute to the enhancement of the Volvo Group’s high-tech competitiveness and technological expertise. eLION platform helps electrify mobile machines

Bosch Rexroth recognizes that electric drives are an important building block for future viable, sustainable mobile machines. To www.fluidpowerworld.com

THE MODULAR AND SCALABLE REXROTH ELION PLATFORM FOR THE ELECTRIFICATION OF MOBILE MACHINERY INCLUDES MOTOR-GENERATORS, INVERTERS, GEARBOXES, SOFTWARE AND ACCESSORIES AS WELL AS MATCHING HYDRAULICS. | COURTESY OF BOSCH REXROTH AG support and encourage the electrification of off-highway equipment, the company offers its eLION product portfolio, which covers a wide range of components, including a full range of electric motor-generators, inverters and accessories as well as tailored gearboxes, hydraulics and software.

According to Matthias Kielbassa, vice president electrification, the three most important properties of the new product platform are scalability, robustness and functional safety. Thanks to a modular design, the electric 700 V eLION motor-generators from Bosch Rexroth cover a nominal power range from 20 to 200 kW (peak power up to 400 kW) and deliver nominal torques of up to 1,050 Nm and maximum torque of up to 2,400 Nm. They are available in four sizes with different lengths and winding configurations and, depending on the design, in a fast or standard-speed version. Over 80 configurations are possible, which means maximum design freedom for manufacturers when electrifying existing and new vehicle architectures. eLION inverters are available in various power classes with up to 300 A continuous current and high overload capacity. The

inverters support dc bus voltages from 400 to 850 V. Gearboxes with high power density for hub and central drive configurations (eGFT and eGFZ) are also part of the eLION portfolio and allow compact drive units for a wide range of applications.

Rexroth BODAS software modules are available for the entire eLION platform, along with matching hydraulic components such as axial-piston pumps. Other electrical components such as dc/ dc converters, power distribution units, on-board chargers and high-voltage cables round out the range. As a result, manufacturers can rely on integrated solutions, irrespective of the energy source (for example, hybrid or battery).

The new components also stress a focus on operating conditions and functional

safety. According to Kielbassa, eLION engineers relied on the company’s own experience with electrical industry systems and its comprehensive knowledge of the mobile working machine sector throughout the development process.

The eLION motor-generators and inverters are highly robust: both comply with the IP69K ingress protection requirements and can be used at a temperature range between -40°and 85° C. The maximum temperature for the motor-generators is as high as 100° C. Mechanical and structural resistance of the eLION components is up to 50 g for shock and 10 g for vibration.

A particular focus during product development was on functional and electrical safety.

Manufacturers and users benefit

from inverter safety functions in accordance with ISO 13849.

Eco-friendly electric drive filtration technology

The mobile hydraulics industry is experiencing a major transformation toward electrification, said Jeremiah Allshouse, Product Manager, Element Technology, for Schroeder Industries. “These electrichydraulic systems hold the potential to be drastically more energy efficient than the typical hydraulic system counterparts that exist today, and much more environmentally friendly.”

As one example, engineers are looking to incorporate electrichydraulic motor pumps to power hydraulics throughout a machine.

“Electric-hydraulic motor pumps only operate when flow and

TOUGH CYLINDERS FOR TOUGH EQUIPMENT RAM Custom Heavy-Duty cylinders have a robust cylinder design for OEM equipment operating in demanding working environments.

Count on RAM for reliable hydraulic cylinders produced with high-quality materials selected specifically for each application.

Nitride rods provide protect in high corrosion conditions High or low temp seals operate in extreme operating temperatures Custom rod bellows bell protect against abrasive particles RAM will work with you to configure bore sizes, stroke lengths, and mounting options to meet your design and performance specifications.

Contact the RAM team today!

RAM Industries Inc www.ramindustries.com

T: 1.877-799.1005

pressure are required to perform the working task at hand. So, when there’s no flow or pressure required, the electric-hydraulic motor pump units switches to a zero-energy mode, and that will save the consumption on energy and increase the overall system’s efficiency,” said Allshouse.

The motor pump devices are up to 70% more efficient than the standard hydraulic counterparts.

Their CO2 reduction is far greater, they are more compact and lighter, and they use less fluid, run quieter, and have a longer life — especially in terms of bearings and seals, he said.

Machine builders also need to reduce power consumption and extend battery life through increased hydraulic efficiency, he continued. One way to accomplish that is to reduce the overall pressure drop in a hydraulic

M O B I L E

COMBINED WITH PARKER HANNIFIN’S GVM310 GLOBAL VEHICLE ELECTRIC MOTOR, THE P1M SERIES AXIAL-PISTON PUMP PICTURED HERE DELIVERS HIGHER SPEEDS AND EFFICIENCY THAT INCREASES MACHINE PRODUCTIVITY TO CREATE AN EFFICIENT ELECTRIFICATION SYSTEM.

system. Differential pressure is defined as the loss of energy available in a hydraulic system, energy that is converted to heat and no longer available to do useful work.

“All energy has a price and wasting it means wasting money,” said Allshouse.

Especially in higher-horsepower systems, even a small pressure drop will cause the pumpmotor group to work harder to make up for that loss of energy, costing more money and shortening component life. Reducing pressure drop can save thousands of dollars per year in operating costs.

To minimize pressure drop in these electrohydraulic systems, Schroeder Industries has developed a new filtration media technology, called Electric Drive Media, or E-Drive Media for short. E-Drive elements consist of multilayered synthetic-fiber filter media, which is an excellent choice for use along with electric-hydraulic drive motor pump units, said Allshouse.

E-Drive filters are characterized by an unusually low pressure drop across the element, making them energy efficient and suitable for low energy consumption requirements compared to conventional hydraulic elements under the same ambient 40

FLUID POWER WORLD

2 • 2022

H Y D R A U L I C S

conditions. “Our current estimations are about 30% less differential pressure than typical synthetic media, which has equivalent energy savings of about 30% less work required on the electric drive motor pump units,” he said.

They are also great for cold-start conditions where a low-pressure drop is required, he continued. The company will initially offer 10 µm media, with the goal of adding in 8 and 15 µm filtration in the near future. Element collapse rating is 145 psid (10 bar), temperature range is-22° to 212° F (-30° to 100° C) and flow direction is outside-to-inside. It is currently rated for 8, 10, & 15 µm filtration.

E-Drive Media can help conserve energy bills, especially in applications where high viscosity fluids are employed and particularly at low temperatures that produce a cold start behavior.

The goal of designs such as the E-Drive media is to reduce fuel consumption by optimizing fluid volume requirements.

Enhanced fluid conditioning will extend time between oil changes and allow users to manage fluid health to maximize its useful life.

Complete electrification system for mobile machinery

At MinExpo last fall, Parker Hannifin’s Hydraulic Pump and Power Systems Division released a complete electrification system spotlighting its new GVM310 global vehicle motor and P1M series mobile open-circuit, medium-pressure axial-piston pump.

The GVM310 is a powerful, rugged, electric vehicle motor for both heavy on and off-road vehicles, engineered for traction and electrohydraulic pumps (EHP) up to 409 kW peak power. With a ten-year legacy and thousands of units sold, the high-power density and speed capabilities of Parker GVM motors combined with a voltage matched inverter provide the speed and torque required to achieve breakthrough www.fluidpowerworld.com

performance, superior efficiency, in a variety of hybrid and electric vehicle platforms.

It is rated for power up to 228 kW (continuous) and peak torque up to 1430 Nm. A variety of available magnetic options allow for a wide range of voltage, speed, and torque requirements. The GVM family achieves high power density thanks to a patented liquid cooling system, which also results in a cleaner, less complex, oil-free design. The GVM310 is an example of how Parker is providing the building blocks for vehicle electrification, developing turnkey technologies that cut time to market while reducing supply chain complexity.

Parker’s P1M series axial piston pump delivers high speed and efficiency, reduces costs, and extends pump life in a robust, compact envelope. It features a patented inlet and optimized port plate design, which increases speeds and improves durability, standard dual shaft seals for wet PTO mounting, and extensive, modular control options, which enable complete circuit customization. Its nine-piston design also reduces pressure ripples.

A patented inlet design on the P1M increases speed ratings and fill capabilities while reducing erosion, cavitation, and pressure ripples. Because it features a compact package, it fits into tighter spaces and offers best-in-class power density due to higher pressure ratings, speeds, and efficiency. Optional dual shaft seals are available for wet PTO mounting for all sizes.

The pump and motor work together to create an efficient electrification system for a wide variety of applications ranging from mobile construction equipment to large mining trucks.

“With the recent merger of Parker’s EMD’s electric motors and gearboxes, Parker HPS is focused on the future of both electric and hydraulics solutions.

By combining electric motor technology and hydraulic pumps, HPS is confident we can deliver highly integrated and versatile electro-hydraulic functions for a wide variety of applications,” said Keith McDonald, product manager, Hydraulic Pump and Power Systems Division.

FPW

Hydraulic Cylinders Hydraulic Valves Hydraulic Power Units Motors & Pumps Joysticks & Handles Control Electronics Hydraulic Components

THE BAILEY ADVANTAGE At Bailey, we build high-quality hydraulic systems. From off-the-shelf components to custom products manufactured to your specifications, we deliver a full range of mobile and industrial hydraulic solutions. We have thousands of in-stock products, strategically located nationwide for quick delivery.

We provide dedicated engineering support, flexible inventory management options and more than 45 years of hands-on hydraulics expertise to help you succeed.

BAILEYHYDRAULICS.COM | 1-800-800-1810 | SALES@BAILEYHYDRAULICS.COM

P N E U M A T I C S

—

F L O W

C O N T R O L L E R S

Precise control through

electropneumatics Electropneumatic flow controllers provide precise control of air flow to actuators, ensuring reliable and consistent speed and motion.

By: Justin Fluegel, Contributor

Adjusting flow electronically allows actuator speed to be controlled in real time. | courtesy of Shutterstock

42

FLUID POWER WORLD

Pneumatics - flow controllers FPW_vs3.indd 42

2 • 2022

www.fluidpowerworld.com

2/11/22 2:10 PM

An electropneumatic flow controller provides precision control of the flow of a gas to an actuator — representing the latest flow control option. They are most commonly used to control the flow of air to an actuator; thereby controlling the speed which the actuator extends/retracts or rotates.

To appreciate the advances that electropneumatic flow valves provide, it is important to understand the mechanical technology they are built upon.

A simple way to control the flow of gas to an actuator is a needle valve. This requires a person to manually turn a knob that gradually slides a needle into an orifice reducing the flow. A limitation of this method is that the air going into and out of the actuator is controlled by the same valve.

The next advancement in flow control was the integration of a check valve into the valve. This allowed for control of the flow into or out of the actuator so the return path can open and pass around the orifice.

While both valves provide excellent speed control of actuators, their limitations result from their manual adjustment and one flow point. A common issue in pneumatic systems is that as the actuators wear, the speed is reduced, the seals wear and the flow controls need adjustment.

An electropneumatic flow control provides an automated process for adjusting the flow control, addressing the wear example and helping to maintain the machine by providing early warning of service or replacement needs on the actuators. They can control the speed of an actuator using a sensor for a feedback

loop. For example, in a pneumatic cylinder with a linear position transducer sending the location of the cylinder rod as it extends, the electropneumatic flow valve can provide more air, which allows the cylinder to rapidly extend and then slow down when reaching a point where the cylinder is to generate force.

While this example improves the control and knowledge of the actuators in a pneumatic circuit, proportional flow control valves provide two additional control strategies for designers — compensating for pressure changes coming into the system or for flow variations. This provides a more reliable performance of the circuit or machine.

How do they work?

Controlling the flow of air within a pneumatic circuit can be done with an electropneumatic mass flow control valve. Flow within a fluid power circuit is hard to visualize. For a pneumatic system, imagine having just inflated a balloon, holding the end of balloon tight admiring the efforts of your huffing and puffing.

You now adjust your fingers and watch the balloon deflate: faster or slower depending on how tight your fingers compress the opening to the balloon (orifice).

Electropneumatic flow valves combine the flow control with an electrically controlled proportional solenoid. These valves require either a controller of their own or the control signal is integrated into a PLC. What makes these valves unique is the flow can be adjusted electronically in real time based on feedback from the machine.

Electropneumatic flow control valves are used in applications where it is important to control the revolutions per minute of a pneumatic motor or speed of the linear actuator in machinery, such as this plastic roll machine. | courtesy of Shutterstock

www.fluidpowerworld.com

2 • 2022

FLUID POWER WORLD

43

P N E U M A T I C S — C O N T R O L L E R S

F L O W

C O N T R O L L E R S

This allows the speed at which the actuators move to be controlled.

The electrical solenoid can be actuated by either voltage or amperage from the controller/PLC. Typically, a voltage drive solenoid uses 0 – 10 voltage direct current (Vdc), while an amperage driven solenoid uses a current of 4 to 20 mA. These electrical values are programmed in proportion to the mass flow rate of the electropneumatic flow control. As an example, 1-V change in the voltage to the solenoid would change the flow by 10 scfm in an application with a range of 0-100 scfm. Mass flow valves are also sized in metric using liters per minute (lpm).

An important nuance between hydraulic and pneumatic mass flow controllers is the impact of temperature on the performance of the valve. In a hydraulic system, temperature impacts on the compressibility of the liquid are less noticeable; however, in pneumatics, the impact of temperature is noticeable on the density of a gas.

Please recall the ideal gas law PV = nRT. (P) Pressure times (V) volume = (n) amount of gas times(R) ideal gas coefficient times (T) is temperature. As the

Engineered for maximum performance at minimum size

Manifold, DIN rail and panel mounting are valuable options for many applications. Units like the durable MM closed-loop valve offer electronic control of pressure and provide flexibility with mounting and accurate, repeatable, customizable pressure control from vacuum through 175 psig. | courtesy of Proportion-Air

FITTINGS

QUICK DISCONNECTS

PRESSURE REGULATORS

VALVES

www.beswick.com

603-433-1188

temperature of a gas increases, the density of the gas decreases in a direct correlation which the volume of gas increases.

Depending on the temperature range of the air entering the valve, it might require an electropneumatic flow valve that compensates for the air temperature or be programmed into the PLC. This will maintain a constant flow rate through the valve regardless of temperature.

Where are they used

Flow in a fluid power system is synonymous with the velocity of an actuator. Electro-pneumatic flow control valves are used in applications where it is important to control the revolutions per minute of a pneumatic motor or speed of the linear actuator in machinery, such as the plastic roll machine pictured.

Both require feedback information to the controller to regulate the mass flow. For a linear speed control, such as speed of a pneumatic cylinder, a linear variable displacement transducer (LVDT) allows the controller to have the velocity of the cylinder and adjust the mass flow to it to directly reduce or increase the velocity of the cylinder. In a rotational control scenario, such as with a pneumatic motor, a rotary encoder can provide the controller with angular speed of the shaft. This feedback allows the electropneumatic flow controller to adjust the speed to meet system requirements.

Outside of a pneumatic system on a machine, electropneumatic flow controllers can be used to control other functions in processes and machinery.

These valves can be found in lasers, paint lines, and liquid spray coating applications. Injection molding either with metal or plastics benefit from using electropneumatic flow control valves to measure amount of material being injected into the mold or quench temperature control by controlling volume of coolant in the system.

Medical device manufacturers use proportional flow control valves to assist with regulating the amount of oxygen a patient receives when on a ventilator. Another medical device using pneumatic flow control valves is anesthesia machines, to mix the medical gases into the air to anesthetize patients prior to surgery.

Opportunities for these valves continues to grow. As demand for precision volumes and speeds in movement of gases improves, and the speed which controllers can process information, these valves will become more common place in systems.

Maximize

FPW

www.kpm-usa.com 2 • 2022

FLUID POWER WORLD

45

Kawasaki Precision Machinery (U.S.A.) Inc. Grand Rapids, MI • www.kpm-usa.com • 616.975.3100 DISTRIBUTION OPPORTUNITIES AVAILABLE

PRODUCT WORLD

Intelligent hydraulic power unit

Hydraulic hose and couplings

INKA intelligent compact power unit is flexible in height, size and pump combination and can be used with HAWE’S wide range of valve products.

The new communication box makes it easier to install the unit quickly and easily and provide visual feedback about the unit status. With the M12 connector, users can easily connect to important product data and use switching outputs or IO link communication.

The motor sensor is installed into the heart of the power pack to detect speed and oil level and temperature directly in the unit, allowing for condition monitoring or predictive maintenance. The electronics enable the acquisition and storage of operating data, extensive diagnostic options and a self-test for all measuring functions.

Alternatively, a version with three freely parameterizable switching outputs is also available. In this case, any measured variable, such as temperature and fill level, can be assigned to each switching output with the help of a PC application (software) provided by HAWE. The unit can be equipped with a radial piston pump for pressures up to 700 bar or with a gear pump for pressures up to 200 bar. The maximum possible flow rate is 2.2 lpm.

Expanded KWIK-FLEX product line includes the most popular types and sizes of hoses and fittings and is available to customers in both the United States and Canada. The initial product offering includes a variety of different hose types — all of which meet or exceed the appropriate SAE hose ratings. KWIK-FLEX also features some of the most popular fitting types to ensure leak-proof performance regardless of application, including JIC, 45° flare, O-ring boss, O-ring face seal, flange and American dryseal pipe thread.

The KWIK-FLEX line features 600-plus part numbers and covers the most popular industrial applications including agriculture, timber, construction, manufacturing and transportation equipment. The hoses are constructed to move hydraulic fluids at normal flow rates yet engineered to handle a wide temperature range and abrasive conditions.

Top-ported suction filter for pump inlet

SKF3 top-ported suction filter ranges up to 300 psi (20 bar) and for flow rates of up to 25 gpm (95 lpm).

Suction filters help protect downstream pumps from contamination due to ingression or lack of initial cleaning. They must be properly sized to avoid cavitation of the pump.

Suction filters help increase the lifetime of downstream components and reduce the particulate load on finer downstream media and in return increases service intervals and reduces unplanned downtime.

The SKF3 offer easy element change out, a 2.5 psi suction bypass with reliable visual or electrical vacuum dirt alarms. The SKF3 is available with Schroeder’s quality protected GeoSeal elements (GSKF3). The SKF3 can help protect downstream pumps from contamination, ingression, and is a reliable filter that can help maintain uptime while reducing costs due to unplanned downtime in any suction application.

46

FLUID POWER WORLD

2 • 2022

www.fluidpowerworld.com

OFCO

Variable-displacement, bent-axis motors

External gear pumps for mobile applications

Series V16 is a new generation of variable displacement, bent-axis motors and a further development of Parker’s V12 and V14 bent axis motor series. The Series V16 provides customers in the mining industry with increased fuel savings and decreased carbon dioxide emissions in transmission, drilling and other mining applications. It is available in displacements of 220 and 270 cm³/rev.

Parker said the V16 offers best in the world speed capability which allows users to increase their production. It provides smooth, fast and accurate control and maneuverability.

The bent-axis design withstands pressures up to 550 bar.

New range of HY1 and HY2 external gear pumps are used in mobile applications. The HY series is provided with an aluminum alloy housing, two gear wheels supported by sleeve bearings, and cast-iron flange and cover. Available as pumps and motors, they offer high efficiency and can be applied in standard and heavy-duty application. The pumps can be supplied as single, or as multiple units with a variety of options on flanges, shafts and ports.

They offer displacements from 1 to 31.7 cm3/rev (from 0.06 to 1.93 in.3/rev); max continuous pressure of 260 bar (3,770 psi), max intermittent of 290 bar (4,200 psi) and max peak of 310 bar (4,500 psi); and maximum speed to 4,000 rpm.

Two other versions — a low noise and cast-iron body version — are under development and production.

WHERE ARE YOUR FILTERS? If you bought from OFCO, you’d be using them now.

Strainers • Filters • Breathers • Diffusers Stock and Custom Filtration Solutions Ohio Fabricators Company designs and manufactures your hydraulic solutions right here in our Central Ohio factory.

Our quick-ship program for standard products means you receive your shipment within days, not months. Even customfiltration solutions get our unparalleled delivery times.

Proudly Made in the USA • ISO 9001:2015 Compliant OFCO-FPW-012022.indd 1

Call or email our sales team today to check our stock and discuss your specifications.

info@ohfab.com • 888.354.0291 www.ohfab.com 12/13/21 12:19 PM

PRODUCT WORLD

Compact temperature transmitters Noshok noshok.com Upgraded 810 series compact temperature transmitters are available with expanded temperature range options and additional stem lengths.

Features include: • Compact size • Proven PT1000 sensor provides reliability, stability and unbeatable performance • All 316 stainless steel housing and wetted materials • Fully welded construction with M12 electrical connection provides enhanced durability • Standard temperature ranges from –22° to 302° F (–30° to 150° C) • 4 to 20 mA transmitter included • Pressure rating of 3,915 psi (270 bar) • CE compliant to suppress RFI, EMI, and ESD • Ideal for mobile hydraulics, automotive, heat exchangers, HVAC, transportation and refrigeration controls

Environmentally friendly hydraulic fluid Renewable Lubricants Inc. renewablelube.com Bio-Ultimax 1000 readily biodegradable biosynthetic formulas perform like mineral oil-based hydraulic fluids, but are environmentally friendly. With oxidation performance comparable to full synthetics, they are suitable for stationary or mobile environments. Bio-Ultimax super high Viscosity Index (VI) fluids are proven in systems up to 10,000 psi and in systems with ultra-fine filtration. To ensure performance and long life, Renewable Lubricants developed the stringent IsoGreen filtration standard which meets or exceeds the Rexroth pump guidelines for hydraulic fluids.

Non-toxic, zinc-free formulations contain no heavy metals.

With a higher VI than synthetics (Energy Conserving Formulas), Bio-Ultimax 1000 has improved thermal shear stability and increased load capacity. Their extremely low volatility increases the flash and fire safety features, making them safer to use.

A direct replacement for mineral oil-based hydraulic fluids, Bio-Ultimax is ideal for hydraulic systems where low toxicity, biodegradability, and non-bioaccumulation properties are required.

Pneumatic cylinders with automatic mechanical end stroke locks Camozzi Automation us.automation.camozzi.com End Lock pneumatic cylinders are fitted with automatic mechanical end stroke locks which guarantee the safe and secure holding of the cylinder rod in both the fully retracted and fully extended positions. The locks activate and release automatically, without the need for external signals or commands and cylinders Series 63 comply with ISO 15552.

They are suitable for use where it is essential to lock the cylinder’s position, both to avoid sliding during long stops and in situations with an absence of air, for example in transportation, printing and paper and the woodworking industry.

48

FLUID POWER WORLD

2 • 2022

www.fluidpowerworld.com

ALA Industries Limited is a leader in engineering. Leadership in engineering can be seen through teamwork not only within ALA Industries but with our manufacturing companies that we represent.

We aim to create a seamless flow from our manufacturers to our distributors. The combined effort of all affiliated companies help ALA to better ourselves and provide excellent service and products. We focus on delivering outstanding communication, accountability, and transparency with all companies that we work along. ALA Industries is a leader in engineering due to the goal and ability to create and maintain long-term relationships with our distributors and the manufacturers that we represent.

ALA provides a prestigious product line throughout the Americas that aids the maximization of the end users hydraulic systems. The overall goal of ALA Industries Limited is to focus our time and energy not only

ALA INDUSTRIES LIMITED 3410 Delta Dr, Portage, IN 46368 (219) 762-2059 • alaindustrieslimited.com

on the success of our products, but also to be able to acknowledge areas of improvement and fix them within a timely manner. ALA Industries also seeks to expand their product market to help sustainability efforts, such as pitch control valves for wind turbines.

Within ALA Industries, our employees are dedicated, dependable, and respectful to their fellow employees and clients. They have a focus on servant leadership. Overall, ALA Industries Limited has positioned themself as a leader in engineering due to their ability to have open communication with clients alongside providing premier products.

COMPONENT FOCUS

By Josh Cosford • Contributing Editor

What can a digital pressure gauge do that an analog can’t?

If you just want to observe pressure for the lowest cost possible, you can go down to your tractor supply store and buy a ¼-in. bottom mount pressure gauge for the price of a burger combo meal. But all you get is a way to observe pressure. Yes, a pressure gauge is accurate and reliable (maybe not the burger combo equivalent, however), but sometimes you ask for more of your pressure monitoring device.

First off, there isn’t much precision in staring at a sometimes-vibrating needle with delineations every 1,000 psi. However, an excellent digital pressure gauge offers accuracy down to 0.025%, and even if that accuracy provides no value in the average application, other applications take advantage of this accuracy. Accurate observation of suction or case pressure, in some cases, may help when you can measure and observe with precision. Even a terrible quality digital gauge with 0.5% accuracy offers plenty of confidence that what you see in a glance is what the pressure is.

Although analog gauges may come available with sliding indicators that mark the desired minimum or maximum pressure, you must still watch the gauge when such pressure extremes occur. However, digital pressure gauges may use data logging to save the minimum and maximum value and then reset them easily to restart a cycle.

I’m sure you’ve been in many dark corners of a plant where little light shone on the pressure gauge, requiring a flashlight or mobile phone to read accurately. Digital pressure gauges come equipped with backlights, and a press of a button will light up the LCD screen to make readings effortless.

As you’d expect, technology has permeated further than a backlit digital display. Better than a backlit display is a wireless transceiver that sends readings to your PC. Data at your PC offers the advantage of evaluation and analysis through spreadsheets and charts, making them a valuable predictive maintenance tool.

Because analog gauges use markings printed on their face, you’re limited to the units on any given gauge, and if you’re lucky, you’ll get dual units such as psi and bar. On the other hand, a digital gauge may offer as many unit options as are in common use, such as psi, bar, MPa, or even kg/m², depending on your geographic market.

If you weren’t convinced that a digital gauge offers much more than a pressure reading, the more optioned units come available with switching outputs. With so many benefits, it’s easy to see why the digital gauge has become so popular. Although quite a bit more expensive than analog gauges, they continue to drop in price just like all electronics.

FPW

The rugged 1000 series digital electronic gauge from Noshok is rated for compound and standard ranges from 0 to 10,000 psi.

50

FLUID POWER WORLD

2 • 2022

www.fluidpowerworld.com

Knocking Out Contamination WITH INNOVATIVE CLEANING AND SEALING SYSTEMS HOSE, TUBE AND PIPE CLEANING | SEALING SOLUTIONS

CLEAN EASY. SEAL EASY. s r Exceed Meets o & SAE S ISO, NA ess n Clea lin ds Standar

The Ultra Clean System eliminates unseen dirt and grime the cutting and crimping process leaves behind — contaminates that could shut down your machinery indefinitely.

Clean Seal Systems protect your clean assemblies utilizing heat shrink technology to secure a Clean Seal Capsule onto the end of a hose or tube assembly. Eliminating unwanted contamination and excessive cap and plug inventory.

ULTRACLEANTECH.COM 1274 HIGHWAY 77, BRIDGETON, NJ •08302 • TOLL FREE: 800.791.9111 • INTL: +1 856.451.2176 • EMAIL: SALES@ULTRACLEANTECH.COM

AD INDEX

Ace Controls ...........................33 ALA Industries ........................49 AutomationDirect ....................1 Bailey Hydraulics ....................41 Beswick Engineering ..............44 CFC Industrial Training ...........21 Clippard ................................. BC Fluidpowertraining.net .........19 FluiDyne Fluid Power ...............5 GRH Power ...............................9 Hydraulex Global ......................7 Kawasaki Precision Machinery .45 Main Manufacturing ................8

MP Filtri USA ..........................11 OFCO (Ohio Fabricators) ........47 Permco ................................. IBC RAM Industries.......................39 SIKO ..........................................2 Spartan Scientific ...................27 Super Swivels .........................23 Tompkins Industries ..........IFC, 8 Ultra Clean Technologies .......51 Veljan Hydrair.........................35 Yates .......................................13 Yuken ......................................29 Zero-Max ..................................3

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

Let us connect you with industry leading advertisers Which of the above companies interest you in this issue? Follow the below steps and learn more about their products.

Circle above advertisers of interest.

Please fill in your name, company, email address or enter your 9 digit subscriber number Name: ___________________________________________________________________ Company: ________________________________________________________________ Email: ___________________________________________________________________ Subscriber number: ________________________________________________________ Please send your response via email to Rashdown@wtwhmedia.com 52

FLUID POWER WORLD

2 • 2022

www.fluidpowerworld.com

numbers don’t lie

72

108 YEARS operating continuously as a family business 72 YEARS providing hydraulic pumps, motors and accessories #1 QUALITY #1 DEPENDABILITY

1

#1 RELIABILITY #1 CUSTOMER SERVICE

If you like our numbers, you’ll love our products.

Contact us now for a distributor near you. permco.com | (800) 626-2801

Home of the American Champ 1500 Frost Road Streetsboro, OH 44241

Precision

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

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

• • • •

Electronic Valves Proportional Valves Isolation Valves Precision Regulators

• • • •

Toggle & Stem Valves Needle Valves Electronic Pressure Controllers Pneumatic Assemblies

• • • •

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

877-245-6247 CINCINNATI • BRUSSELS • SHANGHAI