Fluid Power World March 2016

March 2016www.fluidpowerworld.com

Safe packaging applications with pneumatics p.38 Mobile hydraulics troubleshooting, part 2 p.46 The lowdown on gauges p.55

PAGE 32

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Advice from the top

2 FLUID POWER WORLD 3 • 2016 www.fluidpowerworld.com

Paul J. HeneyEditorial Director

[email protected]

On Twitter @DW_Editor

I’ve always been intrigued by the corporate structure—or lack thereof—at Sun Hydraulics. As long as I’ve been covering the industry, I’ve been aware that they have no titles. So it was interesting to hear CEO Allen Carlson (the SEC mandates that there be a named CEO and CFO, but Carlson leaves the title off his business card) speak to a group of young NFPA executives at the association’s Annual Conference. The company doesn’t really fit any standard models, and has been profiled by the Harvard Business Review multiple times. There is no organizational chart. They have shared office space, including Carlson. He gets no perks beyond salary—not even a special parking spot. They have no budgets, nor sales forecasts. Yet, this company has grown from a roughly $10 million dollar company in 1985 to one that exceeds $200 million dollars in revenue today. Carlson’s leadership is obviously a huge factor, and he was kind enough to share some of his wisdom with us:

• Sometimes, what’s most important in life is not what you choose to do, but what you choose not to do. Carlson knew he didn’t want to work on the farm, nor be an economist, clergyperson or accountant. Engineering was what was left, and it sounded pretty interesting to him.

• Elevate yourself above the weeds. Carlson kept a daily, weekly, monthly and yearly diary. At the beginning of the year, he’d say, “These are the things I want to accomplish this year.” At the beginning of every month, “These are the things I want to accomplish this month.” And so on. He wrote it all down. By doing that, he said, he would always, at the end of the day, find time to do the things on his checklist that he wanted to do.

• Mix it up. Knowing and doing is similar to the equation Work = Force x Distance. If you know what to do and you don’t get it done, you’ve created no work. If you do all kinds of things that have no value, you’ve created no work. If you are leading a company or a group, mix people up. Make sure you don’t have a whole group that sit around and talk to each other in PhD lingo and nothing gets done. And don’t have a bunch of people that are doing—but nobody knows what to do.

• Perseverance and communication/collaboration are key attributes for anyone you hire. If you have communication without collaboration, not much gets accomplished. If you have collaboration with no communication, usually you get the wrong things done. Carlson said most companies are horrible at this, and email has made it worse.

• Only worry about things that you can control. Stop worrying about those you have no control over. The person who wants to do something finds a way. The other finds an excuse. Be the person who finds a way. FPW

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WTWH Media, LLC6555 Carnegie Ave., Suite 300, Cleveland, OH 44103Ph: 888.543.2447 • Fax: 888.543.2447

EDITORIAL

Editorial Director Paul J. Heney [email protected]@dw_editor

Managing EditorMary [email protected]@dw_marygannon

Associate EditorMike [email protected]@wtwh_Michael

Assistant EditorMichelle [email protected]@wtwh_michelle

Contributing EditorJosh Cosford@FluidPowerTips

Contributing EditorKen [email protected]@FPW_KenKorane

Contributing EditorCarl Dyke@carlindustry

VP, Creative ServicesMark Rook [email protected]@wtwh_graphics

Art DirectorMatthew Claney [email protected]@wtwh_designer

Graphic DesignerAllison [email protected]@wtwh_allison

Traffic ManagerMary Heideloff [email protected]

Production AssociateTracy Powers [email protected]

Director, Audience DevelopmentBruce Sprague [email protected]

4 FLUID POWER WORLD 3 • 2016

2011- 2015

www.nfpa.com

MARKETING

Marketing ManagerStacy [email protected]@wtwh_scombest

Marketing and Events CoordinatorJen Kolasky [email protected]@wtwh_jen

Marketing CoordinatorLexi Korsok [email protected]@medtech_lexi

Digital Marketing SpecialistJosh Breuler [email protected]@wtwh_joshb

Digital Marketing InternAly [email protected]@wtwh_aly

MARCH 2016 • vol 3 no 2 • www.fluidpowerworld.com

NEW MEDIA/WEB/BUSINESS DEVELOPMENT

Web Development ManagerB. David Miyares [email protected]@wtwh_webdave

Web Development SpecialistPatrick Amigo [email protected]@amigo_patrick

VideographerJohn [email protected]@wtwh_jhansel

VideographerKyle [email protected]

Digital Media ManagerPatrick [email protected]@wtwhseopatrick

Online CoordinatorJennifer [email protected]@wtwh_jennifer

Digital Marketing SpecialistAndrew [email protected]

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FLUID POWER WORLD does not pass judgment on subjects of controversy nor enter into disputes 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 publication. Every effort is made to provide accurate information. However, the 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© 2016 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 systems, without written permission from the publisher.

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FLUID POWER WORLD is published by WTWH Media, LLC, 6555 Carnegie Avenue, Suite 300, Cleveland, OH 44103.

Staff Page_Fluid Power World 3-16.indd 4 3/16/16 10:49 AM

CUSTOM SIZES AVAILABLE

Brennan stocks roughly 4 times the selection of our competitors. That means large or small sizes, unusual jump sizes or end combinations, as well as popular sizes are all readily available. And if we don’t carry it, we will make it for you! Because we control the manufacturing process from end-to-end, we can offer the widest variety of sizes, materials, platings and coatings, even custom engineered solutions.

VISIT US AT BRENNANINC.COM/EXTRAORDINARY CALL US AT 800.331.1523

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18


ON THE COVER The bioWAVE wave-energy converter is equipped with an O-Drive system to convert wave motion into hydraulic flow. Here, the O-Drive is prepared for testing. Image courtesy of BioPower Systems.

32

D E PA R T M E N T S

02 Editorial 08 Korane’s Outlook

10 Association Watch

14 Distributor Update

16 Energy Efficiency

18 Design Notes

24 Fundamentals

28 Maintenance

30 Training

63 Product World

64 Ad Index

38

46

Mar

ch 2

016

Contents | v o l 3 n o 2 | f l u i d p o w e r w o r l d . c o m

38

2015

revenue over $3 million

55

F E AT U R E S

OFFSHORE TECHNOLOGYHydraulics is key to electricity

from the seaInnovative hydraulics improves the

efficiency and economics of wave-energy converters.

PNEUMATICS Pneumatic technologies ensure

packaging applicationsImproving pneumatic safety is critical to successful,

efficient packaging equipment.

MOBILE HYDRAULICSMobile hydraulics troubleshooting

Taking a methodical approach is the best way to get off-highway equipment working

again, quickly and safely.

GAUGESThe lowdown on gauges

Accurately measuring pressure, flow and temperature is critical in any fluid power system, so knowing which gauge is best

suited to your application is key to safe, efficient design.

2016 OTC SHOW PREVIEWThe OTC prepares to bring new wave

of great ideas in 2016Every year since 1969, the

Offshore Technology Conference (OTC) has met at NRG Park (formerly Reliant Park)

in Houston.

60

Contents_FPW 3-16_Vs3 MG.indd 6 3/16/16 9:44 AM

· Custom Hydraulic Cylinders Bore size: 1.6 to 60 inches Stroke: up to 600 inches

· Piston Pumps Displacement range: 28cc to 270cc

· Mobile/Industrial Valves High efficiency, low fuel consumption Low pressure drop Precise controllability

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Blueprint for Bauma

As a showcase for fluid-power innovation, Bauma is about as good as it gets. For starters, the tri-ennial construction and mining-equipment exhibition being held this April in Munich is massive. So much so, it’s reportedly the world’s largest industrial trade fair of any kind. In 2013, the show hosted a mindboggling 535,000 visitors from just about every country on the planet. This time around, more than 3,400 exhibitors will feature countless new products and machines of every stripe. Even better, mobile hydraulics will be center-stage for most of it. Bauma promises a hands-on look at the latest fluid-power components, systems and controls that lie at the heart of next-generation offerings from OEMs. As with any great show, the editors of Fluid Power World will track the introductions, industry issues and technology trends. Here’s a few of the topics we plan to address during and after the show, in no particular order.

Business vibes. For many fluid-power manufacturers, mobile equipment is the most-important sector they serve. Is there an air of optimism, or is the market still suffering from slack commodity demand and slow economic growth? Are companies investing in R&D and keeping engineers employed?

Rise of Asia. Are Chinese fluid-power companies making headway globally? What’s the perception and reality of cost versus quality? Are knock-offs a significant issue among traditional suppliers?

Predicting the future. Like concept cars at automobile shows, major OEMs like to give a glimpse of abstract, speculative and sometimes off-the-wall machines still on the drawing board. In that light, what’s on the horizon? And have investments in futuristic platforms like remote and autonomous control taken a back seat to current economic realities?

Gee-whiz designs. How are cutting-edge design concepts and software tools resulting in novel products that up the ante in terms of performance, power-density, user-friendliness and so on?

Precision, electronic controls and IoT. What are the latest thoughts on boosting machine performance through onboard electronics? And is networking hydraulic components to the Internet and Cloud a growing reality or just a fad?

Think green. What’s new on the engineering front to wring more energy savings out of hydraulic systems? Are OEMs moving ahead with hybrid systems and energy-recovery systems? And Tier 5 emissions regulations may be on the horizon. How will that affect hydraulic designs?

Safety. Safety concepts and regulations in different regions and markets vary considerably; some are viewed too stringent and others too lenient. Is there a growing consensus on system and machine safety?

Reliability and condition monitoring. Unpredictable break-downs and premature failures are still the biggest headaches for machine users. How are makers of filtration and fluid systems keeping contamination under control? And how are manufactur-ers predicting faults before problems cause costly shutdowns?

Bauma runs April 11 to 17. Keep up on the action from the show floor at www.fluidpowerworld.com. FPW

8 FLUID POWER WORLD 3 • 2016 www.fluidpowerworldonline.com

K o r a n e ’s O u t L o o k

Ken Korane • Contributing Editor

Korane column 3-16 FPW_Vs2.MD.indd 8 3/15/16 10:08 AM

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ASSOCIATION WATCHASSOCIATION WATCH


Technical School Education CommitteeFluid power education and workforce development is one of the NFPA’s major priorities. To help support a growing number of programs and activities targeted at technical schools and community colleges, it has now launched a new Technical School Education Committee. Maureen Fitzsimmons of Bimba Manufacturing and Marti Wendel of Curtiss-Wright will be volunteering as the committee’s first chair and vice chair, respectively. The new education committee will provide needed direction and support to NFPA programs. This support is expected to increase the number of trained people capable of applying fluid power. The goal is that these people will then be able to connect others to careers in the fluid power industry. The question that the NFPA is now working to answer with regard to the committee is: What role can/should the NFPA play in connecting hiring managers from NFPA companies to candidates graduating from two-year technical schools with fluid power-focused training and degrees? All NFPA members with an interest in these subjects are invited to join the education committee and participate on its

NFPA takes us to school

Edited by: Mike Santora • Associate Editor

conference calls, which will be held on a quarterly basis as the NFPA’s programs in this key area are developed and deployed.

NFPA Foundation Grants bring fluid power to classroomsJane Suminski knows a thing or two about patience; she teaches science to sixth, seventh and eighth graders at Humboldt Park School in Milwaukee. Each trimester she teaches an elective science class on engineering and fluid power to about 30 students. This year, Jane applied for and received a grant from the NFPA Foundation to bring pneumatic lifter kits and tools to these classes. One of these classes focused on preparation for the Fluid Power Challenge event at the Milwaukee School of Engineering (MSOE). The class has been a whirlwind of excitement, creativity, teamwork and cheering. And lots of kids running around. “This gives kids a chance to practice teamwork, which can be sorely lacking in the classroom,” Suminski

Jane Suminski teaches science to sixth, seventh and eighth graders at Humboldt Park School in Milwaukee. This year, Jane applied for and received a grant from the NFPA Foundation to bring pneumatic lifter kits and tools to these classes.

FPW 3-16 Dept Assoc Watch Vs4.MD.indd 10 3/15/16 10:03 AM

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ASSOCIATION WATCH

2 • 2016 FLUID POWER WORLD 1312 FLUID POWER WORLD 3 • 2016 www.fluidpowerworld.com

Although the team from Humboldt Park School did not win a trophy at the Fluid Power Challenge at MSOE, the students “learned how to work with constraints and create something that worked,” said Suminski. And that made all the difference to them. FPW

NFPA nfpa.com

The new education committee will provide needed direction and support to NFPA programs. This support is expected to increase the number of trained people capable of applying fluid power.

and other engineering topics atwww.engineeringexchange.com

Discuss This

It has been said that fluid power is a “hidden giant” because it is so common in every aspect of our day-to-day existence that we have simply overlooked the obvious. There is not a vehicle, ship, plane or train that can operate without fluid power. There is no consumer item, no electronic gadget, and no morsel of food we grow that can exist in enough quantity, at a cost we can afford, without the use of fluid power. The Fluid Power Professional’s Day photo contest was started to celebrate the wonder of fluid power and those in this industry. It’s a fun, creative way to get professionals involved and showcase what they accomplish everyday. The 2016 contest opend January 1, and will remain open for submissions until March 31, 2016. The categories are as follows: • Fun with Fluid Power (geared toward youth) • People’s Choice Award • Fluid Power Professionals in Action • Power Density • Fluid Power in Motion FPW

IFPS ifps.org

IFPS Fluid Power Professionals Day Photo Contest

The Fluid Power Professional’s

day photo contest was started to

celebrate the wonder of fluid power

and those in this industry. It’s a fun,

creative way to get professionals

involved and showcase what they

accomplish everyday.

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DISTRIBUTOR UPDATE


Paul J. Heney • Editorial Director

Motion Industries speaks on trends inU.S., Mexico

Birmingham, Ala.-based Motion Industries recently announced some organizational changes, including appointing Randy Breaux to the position of SVP of Marketing, Distribution and Purchasing. The company also named Kevin Storer as SVP of U.S. Operations and President of MI Mexico. We spoke with Breaux recently about his thoughts on the state of distribution and the Mexican market in particular.

DW: How has distribution changed in the past few years with online purchasing becoming so prevalent?

Breaux: Most of our customers rely on us for technical support along with the products we sell. As such, we are not seeing much change in our customer’s purchasing patterns where they are moving many purchases online. However, we do believe that there are some products and some customers that will continue moving to online purchasing, so we continue to improve our website and product offering, providing customers the ability to do business with Motion Industries in the way they want to. DW: Do you see fluid power distribution moving more toward a subsystem-dominated selling model where engineered solutions are the key? What is Motion’s role here?

Breaux: We do see more engineered solutions being requested by our customers. Motion has invested over the years in a well-trained group of fluid power specialists in the field, supported by fluid power engineers at our corporate headquarters. We believe we have the right people, in the right places, to offer the right solutions to our customers. DW: Can you give historical perspective on Motion’s presence in Mexico. What is Motion’s plan for expansion in Mexico and Latin America?

Breaux: Motion Industries has had a presence in Mexico for a number of years. Most recently, we have added several new locations in Mexico to support key customers. We see Mexico as a growing market and will continue to expand our footprint in Mexico to service existing customers. We also see customers from the U.S. opening factories in Mexico and will do what is necessary to support their needs, as well.

FPW 3-16_Distributor_Vs2.MD.indd 14 3/15/16 10:19 AM

www.fluidpowerworld.com 3 • 2016 FLUID POWER WORLD 1 5

AVENTICS Quick Ship Program. Kjell Lyngstad, Director AVENTICS North American Sales, helps ensure his customers have the high-performance pneumatics they need through our Quick Ship program. It o ers a wide selection of our most popular pneumatic products, ready to ship with fast, reliable delivery that meets or beats market lead times. And standardizing on these products saves time over your system’s lifecycle.

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DW: Are there particular industrial markets in Mexico that you see as strong now, or in the coming year?

Breaux: We presently participate in several key markets in Mexico, including the aerospace and automotive markets. We will continue to expand in markets that are growing south of the border, particularly when our existing U.S. customers request our presence there to provide them the same level of service they have come to know from Motion in the U.S. DW: Anything else about your plans for moving Motion’s Mexico operations forward?

Breaux: Our leadership in Mexico is the best we have ever had. Local people servicing local customers is key. We believe that Mexico will continue to grow at a pace a bit faster than the rest of North America for a few years to come. FPW

FPW 3-16_Distributor_Vs2.MD.indd 15 3/15/16 10:20 AM


ENERGY EFFICIENCY

Compressed air fail: Sheet metal firm learns that size matters

Ron Marshall • For the Compressed Air Challenge

A sheet metal processor went through a plant expansion that more than doubled the size of its facility. To be safe, the plant engineer doubled the size of the plant’s air compressor to 50 hp from the original 25 hp. The original unit was installed with a 120-gal tank and 1-in. lines; thinking that this worked well, the engineer installed the new larger compressor with the same size pipes and tank. The new compressor was activated and became the main unit, with the older 25-hp model put in standby. An auditor assessed the system as part of a program offered by the power utility. The auditor noticed that the 50-hp compressor was lightly loaded at an average of 7% of its capacity—but running all the time. When it loaded, it cycled frequently, even though the control was

set with a wide pressure band. Further investigation showed high differential because the undersized piping was causing restriction, resulting in the compressor control working improperly with system storage. A 50-hp compressor needs piping of 1.5 to 2 in. The local 120-gal receiver was much too small for the compressor; recommended sizing would be between 1,000 and 2,000 gal to allow the compressor to operate with reduced cycles, and even turn off between load operations. This inefficient operation caused the compressor specific power to be 92 kW per 100 cfm produced, more than four times the optimal level. It turned out the plant had expanded but the machinery installed was mostly hydraulic. Most of the new building was being used for storage of product. There was no real need for a new, larger

compressor. The new unit was grossly oversized. The auditor pointed out that the old compressor was more appropriately sized to handle the small load, but even it was oversized. This smaller unit was placed into service for a test, and the power consumption immediately dropped by 40%. Further to this, if large storage is installed, the 25- or even 50-hp unit could turn off between cycles, saving an estimated 74% in power costs. Learn more about compressor efficiency in our next Compressed Air Challenge seminar in your area. FPW

Compressed Air Challengecompressedairchallenge.org

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MP Filtri 1-16_Vs2.indd 17 3/15/16 1:49 PM

DESIGN NOTES Edited by: Mike Santora • Associate Editor

Pumps help telescopic forklifts in military operations

In military operations, equipment with reliability and

precise maneuverability in rough terrain can be a matter of life and

death. When Kalmar needed exactly this for its new RT022 Light

Capacity Rough-Terrain Telescopic Forklifts, the company knew it had

no room for error. Eaton was chosen to supply the hydraulic pumps

and motors. Specifically, Eaton’s DuraForce HPV pumps and HMV motors were chosen for the RT022. DuraForce pumps and motors are widely used in heavy-duty mining and construction vehicles, forestry equipment, concrete pumps, primary metal production equipment, and oil and gas drilling and production applications. All DuraForce products are


The DuraForce design begins

with a rotating kit that replaces

the traditional bronze piston

slipper with a steel version. The

design also features a rigid housing

and hydrostatic bearing to ensure

a reliable component with the

ability to handle extreme duty

cycles with peak operating

pressures of up to 500 bar.

FPW_DESIGN NOTES 3-16_Vs4 MG.MD.indd 18 3/15/16 8:46 AM

www.fluidpowerworld.com 3 • 2016 FLUID POWER WORLD 19

rated for high-pressure applications up to 420 bar, with peak pressures to 500 bar. The HPV series specifically provides axial piston pumps available with displacements from 55 to 280 cc (3.57 to 17.1 in.3). With an automotive drive control, or DuraForce CA control, the pumps and motors create smooth and repeatable vehicle motion, making ground speed predictable and highly reproducible, independent of external factors such as vehicle load and system operating temperatures. The forklifts are used for loading and unloading ISO containers, which carry supplies and ammunition for expeditionary operations. The machines are small enough to drive directly into a container, robust enough to lift up to 5,000 lb, and designed to perform over a life cycle of at least 15 years.


Discuss This

“Eaton’s DuraForce has been fantastic,” said Randy Wingenroth, VP, Product Development, Kalmar. “The performance of the RT022 has met the demanding needs of the application, and this success has been due, in part, to the DuraForce product and the support we’ve received from Eaton.” The DuraForce design begins with a rotating kit that replaces the traditional bronze piston slipper with a steel version. Consequently, the DuraForce product strengthens a traditionally weak link in piston product design. Other design features such as the rigid housing and hydrostatic bearing ensure a reliable component with the ability to handle extreme duty cycle. “Kalmar knew they would need a combination of performance and life characteristics for the RT022 application,”

said Vince Duray, product manager, Eaton. “Eaton’s DuraForce products have been installed on more than 1,000 machines so far, with no issues in the field.” FPW

Eaton eaton.com

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Compact sealing technology on course for expanded use


DESIGN NOTES

Before Hallite, a manufacturer of hydraulic sealing solutions, began

the design process of its 708 bearing, its engineers knew they needed

a more robust bearing with better sealing capabilities. The redesigned

sealing solution featured material technology and design enhancements

to meet the needs of heavy-duty industrial applications. The new bearing

offered OEMs, distributors who partner with OEMs and aftermarket

service providers with the most advanced bearing of its type.

The concept of a plastic bearing is simple; to provide sufficient support to the moving components in any given application throughout the service life of the hydraulic system. However, to meet this simple concept the material must meet the following challenges (not necessarily in order of priority): • wear resistant, yet non-abrasive to any contact surfaces • dimensionally stable through a range of temperatures • compatible with all applicable service fluids • high compression strength and a predictable, non-system threatening failure mode • commercially viable in terms of base cost and ease and consistency of manufacture • consistent throughout all of the above to ensure repeatable and predictable performance and quality.

Clearly the design team had some challenges ahead. To improve the bearing materials, the design team reviewed its existing mining bearing and then worked with their partners to isolate the characteristics most important to the materials. They followed up this initial review with a series of material and product concept tests using their test facilities based in Hampton, UK. The result was the Hallite 708 bearing. It is a fit-for-purpose bearing designed for heavy-duty cylinder applications, such as mining roof supports and forestry equipment. For better alignment and to reduce risk for metal-to-metal contact between moving parts, all 708 bearings have been fully machined to tight tolerances on thickness. It also has an operating temperature range of –40 to 100° C and works best in applications that require high load bearing, compressive strength and

Hallite 708 bearings are manufactured from a

proprietary material developed for use in heavy-duty

cylinder applications. These applications include

mining roof supports and forestry equipment

that need strong load bearing and wear-resistant

capabilities.


3 • 2016 FLUID POWER WORLD 21

wear-resistant capabilities. It was designed specifically for extreme applications where fiber filled bearings are not suitable. “We designed the new 708 for applications that go beyond the load threshold of the Hallite 506 bearing,” said Lee Shek, technical director, China. The material was developed to maintain the pre-set diameter ensuring a snap-in fit into the housing even after significant periods between manufacture and installation. In addition, the low-friction nature of the material ensures that assembly forces are kept to an absolute minimum. It has been tested in underground mining applications and has continued to perform well. Because of this design and release, engineers now have access to a more durable, heavy-duty bearing that is easy to install. FPW

Hallitehallite.com

For better alignment and

lower risk for metal-to-

metal contact between

moving parts, all 708

bearings are fully machined

to tight tolerance on

thickness. Pre-shaped

overlap of the piston

bearing or the open gap of

the rod bearing make for

easier installation. piston overlap rod open

Strain beyond 10% where metal-to-metal contact is most likely, this

graph details the 708’s performance in typical application environments.


Discuss This


DESIGN NOTES


A new pneumatic valve on the

market this month proposes to save users

up to 30% in compressed air compared

to traditional directional control valves. A

unique spool configuration and on-board

microelectronics help achieve this savings

by recycling compressed air.

Launched by Nexmatix, based in St. Louis, the new valves are designed for use in the majority of applications employing double-acting cylinders. The highest savings will be seen in applications with any of the following: long air line lengths (greater than 3 ft), fast cycle times (less than 4 sec), those operating multiple hours per day, or those with large air volume (large diameter or long stroke cylinders).

Valve reduces compressed air waste

Mary Gannon • Managing Editor

Nexmatix valves have been tested by Oak Ridge National Laboratory, which has reported on the feasibility and testing of the lightweight, energy-efficient, additive manufactured pneumatic control valve. The lab’s results confirmed that Nexmatix valves “are as energy efficient as stated.” The report went on to say “measuring air consumption per work completed, the Nexmatix valve was as much as 85% better than” the valve to which it was compared. According to Victoria Gonzalez, Nexmatix CEO, “Our mission is to lower customers’ cost by delivering technology that reduces compressed air, minimizes inventory and delivers relevant data to help manage maintenance of pneumatic systems. Nexmatix is efficient pneumatics, intelligently simple.” Conventional 5/2 and 5/3 valves actuate or extend a double-acting cylinder by connecting supply pressure to one side of

the cylinder while simultaneously exhausting the other side. To reverse or retract the motion of the cylinder, the connection is simply reversed: the side of the cylinder that was exhausted is connected to supply and the pressurized side is now exhausted. In this situation, all of the compressed air used to produce actuation is lost on each stroke. “Conventional directional control valves exhaust 50% of air used during every valve cycle, effectively creating the largest compressed air leak in the plant,” Gonzalez said. “Nexmatix valves recycle compressed air using a unique body and spool design, saving manufacturers 10 to 45% of compressed air.” Nexmatix valves employ proprietary technology that briefly connects the two cylinder ports before exhausting the pressurized side. This effectively precharges the port before it is connected to supply, saving on average, 30% of the compressed air. In milliseconds, the two sides equilibrate, recycling the compressed air left in the

pressurized lines. Afterward, a small amount of air is vented and the source air completes the cycle. For a 5/3 valve, the center position behavior or exhaust-centered, is maintained during power down. Nexmatix has launched ISO 15407-1 and 15407-2 26-mm valves and ISO manifolds. Later this year, the company expects to launch an 18-mm size and ISO 5599-1 and 5599-2 Size 1. Forthcoming Nexmatix technology, due for release in late 2016, will provide similar compressed air savings when used with single-acting cylinders.

The Nexmatix valve boasts up to 30% compressed air savings compared to conventional directional control valves.



Nexmatixvalvesaredevelopedasplug-and-playforexistingISOvalves,offeringaseamlesschangeover,withnoprogrammingorwiringchangesrequiredbytheend-users. Thecompanyistargetingindustrial,foodandpackagingmanufacturers.InadditiontotheresearchdoneatOakRidge,itiscurrentlyimplementingtestmanifoldsatvariousindustrialsites.Severalsmalltestsusingin-lineflowmeterstomeasureairshoweda28.9%reductionincompressedairusedwhencomparingamanifoldofconventionalvalveswithasimilarmanifoldofNexmatixvalves,Gonzalezsaid. Thecompanygotitsstartattheuniversitylevel,withresearchthatwasdoneatVanderbiltUniversitybyDr.MichaelGoldfarb.Nexmatixnegotiatedanexclusiveworld-widelicensetothetechnologyin2012anddevelopedthetechnologybyincorporatingitintoconventionalvalveswithNationalScienceFoundationgrantmoney.InMarch2014,NexmatixdecidedtolaunchitsownlineofISOvalvestomaximizetheeffectivenessofthetechnology. AsGonzalezputit,thetechnologyisnowinplacetocreatethesevalvesandit’stimetoexploitaseeminglyobvioussourceofenergysavings. “Nexmatixtechnologyhasbeenmademorefeasiblebytherecentavailabilityofultra-compact,low-costmicrocontrollertechnology,whichenableourvalvestoprovidesignificantcompressedgassavingswithoutcompromisingoncost,compatibility,orperformance.ThevaluepropositionofNexmatixtechnologyisfurtherstrengthenedbythegrowinginterestinreducingenvironmentalimpactintheindustrialsector,”Gonzalezsaid.“TheNexmatixvalveisa21stcenturyconcept—enabledby21stcenturytechnology,andcreatedinthecontextof21stcenturysensibilities.”FPW

Nexmatix nexmatix.com


Discuss This

Nexmatix valves brieflyconnectthetwocylinderportsbeforeexhaustingthepressurizedsidetoprechargetheportbeforeitisconnectedtosupply.



How does extreme cold affect hydraulic hose?

In the classic science-museum demonstration, a technician—wearing a white lab

coat and safety goggles—dips a soft rubber ball into a container of liquid nitrogen and then

flings the ball against a wall. Predictably, and to the delight of the audience, the now

rock-hard ball shatters into a thousand pieces.

Ken Korane • Contributing EditorFUNDAMENTALS

The same outcome isn’t so funny when using the wrong hydraulic hose in extreme cold. That’s because elastomers that make up the cover and inner tube of rubber hose, when cooled to sufficiently low temperatures, no longer behave in a readily deformable manner. Instead they become hard, stiff and brittle. Materials-engineering textbooks associate this with thermal changes that affect molecular behavior. At ambient temperatures, an elastomer’s polymer chains have sufficient energy to let them rotate and vibrate, and on a macro scale that gives the material flexibility. As temperatures drop, however, motion in the polymers slows. Eventually, this causes the elastomer to become tough and leathery.

Hydraulic systems routinely operate in extreme cold.

Fundamentals_FPW_3-16_Vs4. MG.MD.indd 24 3/15/16 9:31 AM

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FUNDAMENTALS

With further cooling, the material reaches the glass transition temperature, Tg. Glass transi-tion is a reversible change in an amorphous polymer where physical properties change from leathery to glasslike material. Tg is usually a narrow temperature range, rather than a sharp point like the freezing or boiling point of a sub-stance. An elastomer’s usefulness at low tempera-tures depends on whether it remains above its Tg. At or below the glass transition, temperature, stress, strain and impact loads will damage and fracture the elastomer. It is also important to note that elastomers, such as those in hydraulic hose, can degrade when subjected to thermal cycling. Although elastomers may operate within their stated mini-mum and maximum temperature limits, prob-lems can crop up when elastomers are heavily plasticized or include additives that give low-temperature flexibility. In these cases, additives

can leach out at elevated temperatures, which reduces performance capabilities on subsequent low-temperature excursions. Hose manufacturers rely on cold-flexi-bility tests, using guidelines like ISO 10619, to design and rate their products. When tested, the sample’s tube or cover should not crack; and when warmed to ambient temperature, the test piece should not leak or crack when subjected to proof pressure. In operation at very low temperatures,

hose can exhibit fine radial cracks on the cover surface and the inner tube. Mainte-nance personnel should routinely inspect hoses operating under such conditions and immediately replace those with noticeable damage. Rubber blends in typical hydraulic hose are rated for cold-weather operation to –40° F (–40° C). A number of hose manu-factures do offer a wide range of products suitable for lower temperatures though. FPW


Gates PolarFLex hose is rated for temperatures from –70° to 212° F (–57° to 100° C). The Global G2L version, for example, has two-braid steel wire reinforcement and meets 100R2 Type AT specs. It has a Nitrile tube and Neoprene cover.

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Conference2016TechnologyFluid Power

Presented by

J U N E 2 1 - 2 2 , 2 0 1 6M i l wa u ke e S c h o o l o f E n g i n e e r i n g ’ s Ke r n C e n t e r

I n t r o d u c t i o n t o h yd ra u l i c s p a r t I

I n t r o d u c t i o n t o h yd ra u l i c s p a r t I I

E l e c t r o - h yd ra u l i c c o m p o n e n t s a n d s y s t e m s

H o w t o m a i n t a i n & t r o u b l e s h o o t h yd ra u l i c s y s t e m s

F l u i d p o w e r c i r c u i t b a s i c s

R E G I S T E R O N L I N E

F o r m o r e i n f o r m a t i o n v i s i t : f l u i d p o w e r t e c h c o n f e r e n c e . c o m

Carl Dyke, CD Industrial Group

Tom Wanke, MSOE

Aleksandar Egelja, Caterpillar Inc.

Expert Presenters

What’s In The Conference?P n e u m a t i c s m a i n t e n a n c e & t r o u b l e s h o o t i n g

A d va n c e d t r o u b l e s h o o t i n g & m o t i o n c o n t r o l

S y s t e m m o d e l i n g a n d s i m u l a t i o n

A d va n c e d m o b i l e w i t h l o a d s e n s e h yd ra u l i c s

F i l t r a t i o n a n d c o n t a m i n a t i o n

FP Tech Conference 3-16_Vs3.indd 7 3/16/16 11:01 AM

Josh Cosford • Contributing EditorMAINTENANCE

1 Keep your oil clean. This should go without saying, but I wouldn’t have to say it if the majority of hydraulic failures weren’t still from contaminated oil. Filter your danged oil.

Dirt particles love to move back and forth inside a cylinder, so it’s especially important to ensure oil is clean the first time it makes its way into your cylinder. Install high-efficiency filters in your hydraulic system, and ensure they’re changed when required. A differential pressure gauge or pop-up indicator can tell you when a filter is clogged, which will allow you to change it out before it goes into bypass, a condition when oil passes through the housing unfiltered.

2 Inspect your cylinder regularly. Have a look at the condition of the rod for corrosion, pitting and uneven wear. Corrosion could signal excessive moisture, either ambient or

within the fluid. The latter scenario is worse, as it spells disaster for your entire hydraulic system. Rod corrosion will accelerate seal wear, as friction damages the rod seal and wiper. Pitting on the rod can occur from corrosion, but also from physical damage, which will also lead to seal damage. Uneven wear of the rod is often a result of misalignment. Side load causes the rod to rub on one side of the bearing, which can prematurely wear the bearing, seal(s) and rod itself. In most cases, a corroded and damaged rod can be re-chromed and/or polished to refinish it. If the rod can’t be repaired, it can be manufactured by any cylinder repair shop. Before re-installation, it would be wise to remedy the problem causing the damage in the first place, or you will find yourself in the business of changing the cylinder often.


5 tips for cylinder maintenance

Differential pressure gauges indicate when a filter is clogged, which will allow you to change it out before it goes into bypass. Image courtesy of

Noshok

Careful inspection of cylinders is necessary on a regular basis to check for corrosion, pitting and uneven wear. Image courtesy of istock

FPW Maintenance 3-16_Vs3 MG,MD.indd 28 3/15/16 9:34 AM

5 tips for cylinder maintenance3 Rotate your cylinders. If downtime is an absolute impossibility, you may

want to keep a set of spare cylinders you rotate into service on a regular basis. This will keep your cylinders fresh in spite of high risk particle contamination or extreme operating conditions. Once one cylinder is removed from service, it can be disassembled, inspected and repaired if required. When a cylinder is in pieces, it’s a good idea to replace all seals, since they’re typically very economical. Inspecting the internals of your cylinders on a regular basis also gives you clues to the condition of the rest of your hydraulic system. The occurrence of varnish, for example, could mean your oil is running continuously hot, and you may need to address operating temperature. Also, a physical inspection of the piston and cap can tell you if particles have been trapped within the cylinder. If it looks like someone was beating your piston with a ball peen hammer, then I can guarantee a chunk of metal has been slapping around inside for months or years. And if it made its way into your cylinder, it existed elsewhere in the system, too.

4 Service your accessories. The brackets, clevises, rod eyes, ball joints or other connections to a hydraulic cylinder are nearly as important as the

cylinder itself. When a pivot pin or clevis is worn, there is excessive slop and play in the joints of the cylinder. This will cause misalignment, which could lead to rapid wear or catastrophic damage in some cases. If you have a high precision machine, even a few thousandths extra clearance between each joint can cause jerky, inaccurate motion and vibration. When a cylinder is removed for servicing, it is a best practice to inspect and replace the accessories, if needed. A pin is only a few bucks, and is meaningless compared to a thousand dollar NFPA cylinder. Just as with other parts of your hydraulic machine requiring lube, grease the cylinder joints on a regular basis to prevent uneven or excessive wear. An ounce of prevention goes a long way.

Inspecting your lube oil system is critical when using pneumatic cylinders. FRLs are reliable sources of lubrication, but you should inspect them regularly and top off as needed. Image courtesy of Clippard Instrument Laboratory

5 Inspect your lube oil system. If you are running pneumatic cylinders, which often need their own

source of lubrication, inspect and service your lubrication system, as needed. A basic system will have a lubricator built into the filter/regulator assembly, which is fairly reliable. However, no lube oil can be provided when the reservoir is empty. Inspect the oil level regularly, and top off as needed. Even a reservoir full of oil provides no guarantee your lubricator is working, so you may need to test your oil line exiting the FRL by hooking up a blow gun and spraying a white paper towel. If there is a patch of oil on the towel, you’re good to go. If it is dry, you may have to remedy a clog in the lubricator, or replace it if it cannot be fixed. When testing any lubrication system, check that excessive amounts of oil aren’t being introduced into the system. I’ve seen lube systems introducing so much oil as to hydrolock a pneumatic cylinder, preventing it from cycling full stroke rapidly. Only a fine mist is required to help an air cylinder overcome friction. FPW


Discuss This


FPW Maintenance 3-16_Vs3 MG,MD.indd 29 3/15/16 9:33 AM

TRAINING

Hydraulic power plant efficiency


David Marlowe • Owner/CEO • DMAR Technical Training and DMAR Business Centers USA

Imag

e: is

tock

ph

oto

.co

m

In previous issues we have discussed fluid and flow characteristics, reservoir sizing and purpose, suction pipe size with fluid flow re-quirements, strainers, filter effects on the pump and the pump itself. Before we continue discussing individual system components, we will discuss how the hydraulic system is divided into three general divisions, beginning with the first division—the power plant.

To understand the transfer of energy, one must understand that energy cannot be created or destroyed. It simply changes face.

a) The definition of energy is “The ability to do work (W).”

b) Work is defined as: Force × Distance = Work F × D = W

c) Power is defined as: Force × Distance / Time = Power F × D = P T

d) Horsepower (hp) is defined as: Force × Distance / Time = Work / Time F × D = W T T

Example: 1 hp equals the amount of energy required to move 33,000 ft-lb (also 746 W), or any calculation that equals the above.

The first division is where combustion energy (engine) or electrical energy (ac/dc motor) is converted to mechanical energy (torque) and mechanical energy is then turned into fluid power (velocity).

The electric motor takes electrical power and converts it to mechan-ical power. To understand how much mechanical power is convert-ed, we must first understand the relationship between horsepower (hp), revolutions per minute (rpm) and torque. To calculate the amount of torque converted we would use the following formula:

horsepower × constant / rpm = torque hp × 5,252

= torque

rpm

The constants are: ft-lb = 5,252 in.-lb = 63,024

FPW_Training 3-16_Vs3 MG.MD.indd 30 3/16/16 11:03 AM

David Marlowe • Owner/CEO • DMAR Technical Training and DMAR Business Centers USA

Themechanicalenergyofthemotorshaftis converted to the mechanical energy to the pumpshaftthenconvertedto(fluidvelocity)powerintothefluid.Fluidpressureisgener-atedbyresistancetoflow. In an ideal world, the horsepower out wouldequalthehorsepowerin(100%ef-ficient).However,thisistotallydependentontheefficiencybetweenthemotor,fluidandpump, design factors associated with the mo-torandpump,properfluidviscosity,operatingtemperature,cleanliness,andfluidflowratefromreservoirthroughpump.Allalignmentswithin the components and to the motor and pumpmustbewithinrecommendedspecifi-cations. Howmuchworktheequipmentcompletescomparedtothecostforthecompletionistheefficiencyofyourpowerplant,whichisdependent on how well you maintain your equipmentandsystem.

There are three choices when it comes to maintenance management of your hydraulic powerplant. Thefirstisthemostcommonmainte-nance management tool used in indus-trytoday:“runtoFailure,”whichoftenmeansignoringit,tweakingit,kickingit,orwhateverittakestokeepitrunninguntilitbreaks,fallsapartandshutsdowntheentiresystem.Theworstproblemwiththismaintenance system is when one com-ponentfails,itusuallytakesseveralothercomponentswithit.Thissystemisalsothemostexpensivetooperate. The second most common management systemisthePreventativeMaintenanceSystem(PMS).PMSisatime-basedmain-tenancecheckonthesystemandcompo-nents.Thissystemreturnsbetterresultsthan“RuntoFailure”does,butthisisthe“one-size-fits-all”optionrecommendedby

theequipmentmanufacturer. ThethirdsystemistheProactiveandPredictiveMaintenancesystem.TheU.S.Navyhasusedthisoneforever.Selectthecorrectequipmenttodothejob,installthesystemandcomponents(us-ingprecisionmaintenanceprocedures)properly.Then,asthesystemisoperating,maintainsystemoperatingtemperaturesandpressureswhilemak-ingadjustmentsasneededtokeepwithinsystemoperatingparameters.Ifitisnotedthataspecificcomponent is failing, shut the system down and replacethecomponent(usingprecisionmainte-nanceprocedures)thenputthesystembackinoperation. Attentiontodetailwillgoalongwayintheoperatingefficiency,maintenancedowntimeandcostsassociatedwithoperatingyourhydraulicpowerplantandsystem. FPW

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FPW_Training 3-16_Vs3 MG.MD.indd 31 3/16/16 11:04 AM

Ken Korane • Contributing Editor


Hydraulics from the sea

Innovative hydraulics improves the efficiency and economics of wave-energy converters.

is key to electricity

Albatern’s offshore array of wave-energy converters uses wave motion to gener-ate electricity. The company is part of a consortium developing the WavePOD hydraulic-electric generator.

FPW_Offshore Technology_3-16_Vs4 MG.MD.indd 32 3/15/16 12:55 PM

O F F S H O R E T E C H N O L O G Y

As the world slowly embraces renewable energy, most

efforts today focus on solar and wind. But tapping the power of the oceans could be the next

forefront of “green” energy.

For one reason, the payoff could be huge. According to the Paris-based International Energy Agency, harnessing ocean waves, tides, currents and temperature gradients to generate electric power could someday exceed the world’s current annual electricity demand of about 20,000 TWh. More realistically, IEA predicts globally installed wave and tidal power arrays could have a capacity of more than 330 GW by 2050. That’s on par with today’s wind energy output, which supplies about 4% of current global electricity demand. A recent report by the Electric Power Research Institute (EPRI) says usable wave energy along the U.S. coastline is over 1,000 TWh/year, and predicts that wave power could eventually provide 10% of total U.S. electricity demand. And in Europe, a number of wave-energy converters have already been deployed. Larger-scale projects of up to 40 MW are expected by 2020 with wholesale market roll-out in 2035, according to the European Ocean Energy Association. Projections are to install up to 100 GW of wave and tidal power capacity in the next three decades.


is key to electricity

FPW_Offshore Technology_3-16_Vs4 MG.MD.indd 33 3/16/16 10:39 AM

Weighing the prospects While such predictions may be optimistic, ocean energy nonetheless offers a number of advantages over other renewables. For instance, waves pack a lot of power, as anyone who has been to the beach can attest. Sea water is about 850x heavier than air, so waves have a much greater energy potential compared to wind or solar. Along the European Atlantic coast the energy density in waves is around 2 to 3 kW/m², around 5x that of wind and more than 10x that of solar, according to researchers at Marine Power Systems, a wave-energy converter (WEC) developer in Swansea, U.K. This means energy can be harvested from rather compact devices, and sizeable amounts of power can be supplied from wave farms that occupy relatively little space on the ocean floor. Furthermore, ocean-energy devices can be located near coastal population centers, which would eliminate the need for lengthy power transmission lines. Granted, the size and frequency of waves varies, but their energy potential is more consistent and predictable compared to that of wind and solar. Wave motion can be forecast days ahead, making it a reasonably reliable power source that’s better suited for grid balancing. On the other hand, successful wave-energy generation faces significant obstacles. As an emerging technology, WECs and the power they generate are currently not cost competitive with even other renewables and, thus, they rely heavily on subsidies for R&D. There are environmental concerns that the devices them-selves, as well as underwater anchor cables and transmission lines,

O F F S H O R E T E C N O L O G Y


BioPower Systems bioWAVE is a prototype 250-kW wave-energy con-verter. A pilot demonstration began in December off the coast of Australia.

Development of a standard WavePOD generator will benefit Albatern’s self-contained onboard Power Take-Off Module.


could harm sea life and delicate marine ecosystems. And more research is needed to better predict the reliability of compo-nents submerged in corrosive and turbulent seawater. On the technology side, numerous wave-harvesting devices have evolved—with varying levels of success—but an optimal design has not emerged. Wave-energy converters harness the energy of surface waves through a number of differ-ent mechanisms. For example, powered buoys, or point absorbers, allow relative, up-and-down movement between the buoy and a stationary, submerged base. Oscillat-ing converters are near-shore devices that capture energy from wave surges. These are bottom-hinged devices where a large arm moves back-and-forth in response to wave movement. Such designs convert wave action into powerful reciprocating action. Many WECs use that to generate high-pressure hydraulic flow—often with hydraulic cylinders—and

capture that energy in a power take-off (PTO) device to generate electricity. Currently, the go-it-alone approach to R&D by individual manufacturers has hindered the success of WECs. Now, however, two projects, in Europe and Aus-tralia, aim to develop a standard “plug-in” PTO that is commercially available to any WEC manufacturer. The goal is to develop an efficient and reliable system using proven components that is both economi-cal and easy to maintain.

BioWAVE O-Drive Ocean energy company BioPower Systems, Sydney, Australia, has developed an oscil-lating converter called the bioWAVE, whose design is said to be based on the swaying motion of sea plants caused by ocean waves. The 26-m-high structure mounts on the sea floor, and three buoyant arms hinged to the

base act as inverted pendulums. Two actions, the rising and falling sea surface and back-and-forth wave movements, cause the arms to slowly oscillate. A pivot near the bottom lets the structure continu-ously self-orient with the wave direction, ensuring that the WEC efficiently captures energy from a

wide range of incoming waves. And to protect the bioWAVE in extreme conditions, say hurricanes, a ballast system fills the arms with water, which drop and lie flat against the seabed. Afterward, driving out the water refloats the arms. WECs face the difficult prospect of converting the large forces and slow motions inherent in ocean waves into a steady flow of electricity. BioPower Systems has reportedly solved this problem by de-veloping an onboard PTO—called the O-Drive—that converts WEC motion into hydraulic power, which in turn is used to run an electric generator. The back-and-forth movement of the arms pro-duces reciprocating motion in two large hydraulic cylinders mounted on the structure. These cylinders pump high-pressure, variable-flow fluid to the O-Drive. Fluid routes through a manifold and is stored in a bank of accumulators. From there, the accu-mulators supply a steady flow to a hydraulic motor that, in turn, directly couples to a standard electric generator. The generator rectifies and smooths the output to produce stable, utility-grade electricity that is transmitted through a subsea cable to the on-shore grid. Low-pressure hydraulic fluid exits the motor and flows to a reservoir and, eventually, returns to the cylinders to complete the hydraulic circuit. The sealed O-Drive houses the hydraulic cir-cuit, electric generator and sophisticated processors that autonomously control the equipment, monitor systems and provide real-time feedback to shore-based operators. The O-Drive can be detached from a moored WEC, which simplifies and cuts the cost of periodic maintenance. A retrieval rig connects to and raises the O-Drive using ballast compartments and air-

The O-Drive mounts on the bioWAVE and converts wave motion into hydraulic flow to run an electrical generator.


O-Drive equipment being prepared for testing at the BioPower Systems facility.



powered winches. Once at the surface, the rig and O-Drive are towed to shore. ApilotdemonstrationofthebioWAVEbeganlastDecemberoffthesoutherncoastofAustralia.Itusesasingle250-kWO-Drive.The plan is to operate and evaluate the system for at least one year. If successful, the company intends to produce a larger, 1-MWcommercialversionofbioWAVEthatwouldusefour250-kWO-Drivemodules.Ultimately,multi-unitwave-energyfarmswilldeliverutility-scalerenewablepowertoonshoredistributiongrids. The O-Drive power conversion module is designed as a “plug-in” PTO for ocean-energy systems. BioPower Systems plans to commercializetheO-Driveandofferittoother project developers. According to com-panyofficials,itcouldprovideasubstantialboosttotheglobalwave-energysectorbyofferingastandardPTOsuitableforanyWEC.TheO-Drivecanalsoconnecttorotary

hydraulic pumps, rather than cylinders, for useontidal-energyconverters.

WavePOD converter Wave-energyfirmsAlbatern,Roslin,ScotlandandCarnegieWaveEnergyUK,Redruth,EnglandalongwithdriveandcontrolmanufacturerBoschRexroth,LohramMain,GermanyarecollaboratingonaprojectcalledWavePOD(WavePowerOfftakeDevice)withtheaimofdesigningastandard,self-containedoffshoreelectric-itygenerator.TheconsortiumalsoincludesIrishutilityESB,whichisdevelopingtheWestwavewavefarmoffthewestcoastofIreland. According to the companies, the projectfocusesononeofthebiggestchal-lenges in wave energy—how to generate electricityreliablyandcosteffectively.TheWavePODPTOisahydraulic-electricgenerator housed in a sealed nacelle that

transformsthereciprocatingmotionofmostWECsintoelectricalpoweroffshore,whichcanthenbetransmittedthroughcablestoshore. In a news release on the program, TimSawyer,projectdevelopmentofficeratCarnegieWaveEnergysaid,“WorkingwithBoschRexrothweintendtocreateanindustry-enablingtechnologywhichwillbeavailableasacommercialproductforarangeofdifferentoceanenergytechnolo-gies. This makes a huge amount of sense for the industry—rather than every company developingitsownpowerofftaketechnol-ogy,WavePODwillbeastandardproductthat frees companies to pursue the devel-opment of their own unique machines, withouthavingtoworryaboutconvertingtheirtechnology’smotionintoelectricity.” Atenth-scale,80-kWprototypeiscurrentlyontestattheInstituteforFluidPowerDrivesandControls(IFAS)atRTWH


FPW_Offshore Technology_3-16_Vs4 MG.MD.indd 36 3/16/16 10:38 AM


Aachen University, Germany. The test rig simulates WEC motion to generate hydraulic flow to the Wave-POD. According to a paper published in the Inter-national Journal of Fluid Power, a basic system has two hydraulic cylinders connected to high and low-pressure lines, and check valves control flow from the cylinders to the WavePOD. An accumulator smooths flow of high-pressure fluid to a variable-displacement hydraulic motor, which then turns a generator. Other hydraulic components include a reservoir, feed pumps, pressure relief valves and filters. Mineral oil serves as the hydraulic fluid. But various WECs interact with waves differently, so a standard PTO must be designed to operate ef-ficiently over a range of inputs. While the basic con-cept uses a single accumulator in the high-pressure line, the actual set-up uses two sets of accumulators with different pre-charge pressures to better reduce pressure fluctuations. Additional accumulators pre-charge the low-pressure lines to the cylinders to ensure adequate flow and avoid cavitation during fast movements. Also, instead of a single hydraulic motor and electrical generator, the prototype has three same-size motors connected to generators. This set-up increases performance at low-power wave conditions by only running a single motor at higher efficiency, rather than two or all three at low efficiency. Fixed-speed, asynchronous generators simplify grid con-nections. The goal of testing is to gage the performance and reliability of individual components and the complete system. Start-up was in November 2014, and results are expected to be published in the near future. FPW

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Discuss This



P N E U M A T I C S

technologies ensurePneumatic


safe packaging applications

FPW_Pneumatics 3-16_Vs3 MG,MD.indd 38 3/15/16 11:50 AM


Erl CampbellFood and Beverage Key Account ManagerAventics

The widespread use of pneumatics technology for packaging machines—to drive motion and actuate machine sequences—has garnered more interest by machine designers and end users as to how pneumatics can improve safety and safe operating functionality in their equipment. This increased interest is due, in part, to the globalization of the pack-aging machine marketplace. Many major packaging OEMs are focused on building machines that can be sold into multiple markets and regions with minimal modifications. To do so, these machines need to satisfy safety regulations—especially for European markets. In addition, machine builders and end users are also discovering that the use of pneumatics that integrates safety technology can also enhance the reliability of their systems and extend their operational life.

Regulatory developments drive pneumatics safety growthGlobally, statutory guidelines for the design and operation of machines mandate a risk assessment to identify potential hazards, minimize risks and

Improving pneumatic safety is critical to successful, efficient packaging equipment.

Machine builders and end users are discovering that the use of pneumatics that integrate safety technology can enhance system reliability and extend operational life.


P N E U M A T I C S

comply with applicable health and safety requirements to protect both people and machines. The main regulatory standard that affects pneumatics technology in packaging systems is ISO 13849, which provides safety requirements and guid-ance on the principles for the design and integration of safety-related parts of control systems. It’s important for machine design-ers to take into account all the moving parts in an axis—a pneumatic actuator or cylinder, for example—and how that motion needs to be controlled to create safety circuits that satisfy the ISO 13849 requirements. “ISO 13849 requires machine manufacturers to apply the recognized rules of good engineering practice and proven safety principles and recommends validation procedures,” said Dr. Rolf Zollner, a leading European safety risk management consultant. “One thing is frequently short-changed: Not only electric controls can be used to realize safety-related controls—pneumatics can also get the job done.”


Packaging equipment relies heavily on pneumatics for safe operating functionality.

It is important to take into account all the moving parts in an axis and how that motion needs to be controlled to create safety circuits ...

Pneumatics-based safety functionsIn short outline, a safety control circuit defined by ISO 13849 has three basic elements: • an input, such as a sensor like a safety door, safety mat or light barrier that detects an event identified as presenting a safety hazard; • a logic that evaluates the hazard, such as a safety PLC or safe pneumatic with pre-programmed logic to respond in a set path based on the sensor’s input; • and an actuator, which initiates the safe reaction, such as limiting speed, reducing pressure or force or initiating a safe exhaust of pneumatic pressure to stop cylinder motion and bring moving machine parts to a safe standstill.

Safe pneumatic circuit design fo-cuses on what happens to pneumatically powered machine axes and actuators when there is a loss of power and the pneumatic circuits are no longer receiving the neces-sary power. When power loss occurs, the pneumatics on a packaging system can be


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P N E U M A T I C S


used to automatically initiate several measures to protect people and machinery, such as reducing pressure and force, safely releas-ing energy and guaranteeing a safe direction of travel or blocking a movement.

Safe exhaust and safe holding functionsSafe exhaust can be illustrated by describing a typical packaging ma-chine that incorporates pneumatic actuators. In a tray-wrapping ma-chine for example, the transparent wrapping material unspools from a roller that is controlled by pneumatic cylinders and valve systems. If there is a jam in the wrapping functionality, sensors at mul-tiple points on the machine detect the jam and initiate a machine shutdown that incorporates safe exhaust. The air is safely exhausted from the pneumatics within the machine in a controlled manner, removing energy from the system and preventing any damage to the equipment; it also ensures that an operator can enter the machine enclosure and safely clear the jam. When safe exhaust is initiated, the valves move to the basic (or default) position to depressurize the system. To ensure successful safe exhaust, there should be two safe exhaust pathways with two valves, so if one valve fails, it is backed up and safe exhaust occurs. Typically, safe exhaust pneumatic circuits require multiple components: two valves, two sensors and an air-monitoring unit.


1 Good leakage values minimize the risk of failure. Pilot air can be controlled internally or externally: if a problem occurs, the valves switch to a defined safe state.

2 The bus coupler provides galvanic separation between logic voltage (UL) and actuator voltage (UA) in the bus coupler. This results in separating safety-related functions from other functions, thereby fulfilling ISO 13849-2 safety principles.

3 The pressure sensor module is used to safely monitor system pressures and provides reliable, fast information about pressure conditions in all relevant modes of operation.

4 The electrical supply plate provides actuator voltage to the valves, enabling independent voltage zones with any number of valves. Safety functions remain separate from other functions.

5 Pressure supply plates enable mutually independent pressure zones for customized pressure supply to different safety circuits and ensure adequate and rapid system exhaust.

6 Exhaust module: in case of an emergency stop, cylinder chambers may remain under pressure. To change the cylinder position (for maintenance or workpiece positioning) targeted system exhaust can disable the cylinder without having to apply energy. Integrating this module in valve systems reduces sensitivity to actuator movements.

7 The pressure regulator module provides safe control of compressed air in the working lines for safe pressures and controlled cylinder movement. Many safety functions can be supplemented by reducing pressure and force.

Safety-related pneumatic features

Design engineers need to be able to selectively control how safe exhaust operates on vacuum cups, for example, where damage can occur if the vacuum is suddenly lost.


Recently, pneumatics suppliers have been creating safe exhaust valves with sensors integrated into the units to simplify wiring and testing of the circuit. In certain circumstances, exhaust-ing the pneumatic system may prevent the machine from being cleared in a timely manner. In the example described above, there may be cylinders that have air trapped in them at safe exhaust (by design), but need to be moved by the operator to clear the jam. In this situation, an alternative safety function called safe holding can be designed into the system and initiated. To move that actuator to clear the jam, it is necessary to open up the ports to that cylinder. Many pneumatic systems

use manifold valves to control airflow to multiple actuators and cylinders, and the newest generation of valves incorporates features that allow operators to send a separate signal to a specific valve to open and allow the cylinder to be moved to clear the jam and restart the machine.


P N E U M A T I C S

Machine builders are also discovering that the use of pneumatics that integrates safety technology can also enhance the reliability of their systems and extend their operational life.

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Safe vacuum control and safe restartVacuum cups and pneumatic grippers are also common actuators in many lightweight packaging applications, used to pick up items and place them in a box, bag or other container. In a situation when the machine initiates safe exhaust, machine designers and packagers don’t want the items held by these actuators to be dropped. Design engineers need to be able to isolate and selectively control these com-ponents on the manifold—electrically and pneumatically. A pilot-operated check valve can be used to lock the cylinder and maintain the grip while the other pneumatics are de-powered. Certain pneumatic manifolds now incorporate features to have auxiliary power supplied to different sections of the mani-fold. In the event of a safe exhaust, a signal can be sent to keep power on to the vacuum side of the valve and reduce or drop the

electrical out of the rest of the manifold. To ensure safety in machine opera-tion and protect against machine damage, some machine builders are also incorporat-ing safe pressurization into their designs. Similar to a “soft start” on an axis driven by a servomotor, it uses pneumatic valving to slowly and safely bring all the pneumatics in the machine up to full pressure at ma-chine start-up or restart; this helps protect against damaging the actuators and other equipment from abrupt starts. This can be highly useful in packaging machines with frequent changeovers for different packag-ing formats or materials. Using B10 and MTTFd to select reliable pneumaticsISO 13849 also provides a framework for establishing and documenting compo-nent reliability. Engineers have to define

Implementing safe dual-channel exhaust with pneumatic products.




Discuss This

a required performance level (PL) in a risk assessment for a given machine function, depending on the probability of occur-rence and frequency of risks, as well as the severity of possible injuries. This PL must be achieved by means of technical safety precautions. Safe pneumatic switching processes and the reliability of the safety-relevant components contribute to these efforts. That reliability is documented using two measures: the B10 value for physical components, and Mean Time To Dangerous Failure (MTTFd) for electrical components.In pneumatic valves, the B10 value indi-cates how many switching cycles it takes for 10% of components to exceed defined limits, such as switching times, leaks or switching pressure under specific condi-tions. Some safe exhaust valves have a B10 of 250,000; others are engineered for much higher levels of reliability, achieving B10 values up to 10 million. MTTFd describes the mean duration in years until a dangerous system component failure. It is a statistical value for electrical/electronic components, which is identified through trials or reliability prognoses based on failure probabilities for the components. In terms of machine safety, ISO 13849-1 only considers dangerous machine failures. These are described by B10d; the dangerous failure number is typically higher by a factor of two, since not all failures would be catastrophic and most compo-nents would only have diminished function once the B10 number is reached.

Extending machine life and valueIt is up to the machine designer to select the pneumatic components for safety circuits based on the ISO guidelines for assessing the safety-related risk factors for a given machine, to satisfy the PL requirements. However, selecting pneumatic components with greater documented longevity is not just purely for safety or purely to align with evolving standards.

New sensor technology is being integrated into many pneumatic valves and other components to capture data ... that can be used for predictive maintenance and replacement programs.

Safety and machine value go hand in hand: pneumatic components documented to provide years of reliable performance enhance operational reliability, reduce maintenance costs and increase packaging equipment uptime—all of which contribute to improved productivity and return on investment. In addition, new sensor technology is being integrated into many pneumatic valves and other components to capture data such as cylinder stroke length and valve cycle counts. This is data that can be used for predictive maintenance and replacement programs to make doubly certain that machine and operator safety is maximized. The ISO 13849 directive has led many top pneumatics technology companies to invest in, document and receive third-party verification of the improvements in reliable operation of their components, as well as enhance how those components can be more easily integrated into safe pneumatic circuits. For packaging machine designers and builders seeking to build globally marketable machines, this presents one more convincing reason why pneumatics remains an important and viable drive technology for their systems. FPW

Aventicsaventics.us


Carl Dyke • Contributing Editor

Mobile hydraulics troubleshooting


Taking a methodical

approach is the best

way to get off-highway

equipment working

again, quickly and

safely.

Part 2

M O B I L E H Y D R A U L I C S

Mobile Troubleshooting Part 2_Vs5 MG.MD.indd 46 3/16/16 10:32 AM

In Part 1 of this series, we examined how to

diagnose a problem, look for simple root causes, and use schematics

as guides. Now, let’s get into a real-world example that you could

encounter.

Example: A small excavator with slow bucket curlStarting with troubleshooting, let’s say that just one function, a cylinder, controlled by its own directional valve is unusually slow while extending and retracting. Other cylinders on separate directional valves, in parallel sub-circuits, are working normally. We’ll say that the unusually slow cylinder function provides bucket curl motion on an excavator, and that the boom and stick cylinders are working fine.

This sounds like a flow rate problem for the bucket curl cylinder sub-circuit.

The schematic (found on page 48) helps us see the sub-circuit components for the control of the cylinders. They are all fed a supply of hydraulic fluid from the same “P” line (red) inside the valve manifold. The di-

rectional valves all exhaust to the same “T” line (blue) that

is routed back to the


Check the drive current to proportional valve solenoids.

Mobile Troubleshooting Part 2_Vs5 MG.MD.indd 47 3/15/16 1:39 PM


tank. Each directional valve provides variable speed (proportional flow) control for cylinder extend and retract motion. The proportional directional valves are operated by variable current solenoids. The directional valves feature adjustable screw stops that limit the maximum travel of the valve spool in each direction, limiting flow rates.

Each cylinder sub-circuit also features a shock relief valve on the lines between the work ports and the cylinder. These valves limit the pressure in a cylinder and its A and B hoses when external forces are acting against the cylinder, while the directional valve is in neutral (A and B ports blocked). Shock relief valves are typically set to the highest pressure of all the pressure controls in the hydraulic sys-tem. A pair of anti-cavitation check valves are also present

to provide makeup fluid to the cylinder on the oppos-ing port from where a shock relief action may have occurred. The technician reads in the manual that it is a single, variable-displacement, pressure compen-sated pump that provides flow for the three cylinder functions. The pump is a bit oversized in comparison

to the size of the directional valves, and therefore large enough to provide flow for all three cylinders to be operated simulta-neously. While the maximum speeds of the cylinders vary somewhat depending on whether they are being operated alone or simultane-ously, the operator

has noticed that the bucket curl cylinder is now very slow even when used alone. Having confirmed the fault and noticing no ex-ternal leaks or any other obvious clues, the technician studies the schematic to confirm the flow paths that

are meant to exist, and to look for others that might come to exist if there was inter-nal leakage. The technician is also looking for any other component that could cause unusually slow travel of the bucket curl cylinder. The technician observes that the flow through the bucket curl directional valve could bypass to tank through any of the shock relief valves or anti-cavitation check valves, if one or more of them were to stick in the partially-open position. An internal leakage path could also exist if the piston seal in the cylinder was failing. Any and all of these internal leakage paths could account for a slow bucket curl cylinder. If the technician starts to plan various tests for internal leakage using flow meters or hand pumps, is she getting a bit ahead of herself? Quite possibly, yes. One of the clues was that the bucket curl cylinder was slow while extending and retracting. If the shock relief valves and/or the anti-cavitation check valves were to be the prime suspects, more than one of them (at least one of two, on each of the two main work lines to the cylinder) would had to have failed simul-taneously. It’s possible of course, but not as likely as a failed piston seal which, as a single component failure, could affect both directions of travel. The technician decides to do further checking in the machine manual and notices that the piston in this particular cylinder has one seal for extend, and another separate seal for retract. Both seals must have failed to cause the problem as observed. The tech-nician wonders what she might be missing. Noticing the adjustable spool travel stops on each valve section—which allow for the maximum opening of the valve to be limited—the technician decides to look closely at the adjustments. It doesn’t look like anyone has made any changes to the settings as the paint on the adjustment screws and jam nuts have no scuffs or chips. The technician checks the manual to see if there are any notes about the normal position or thread length of the adjustment screws and finds none. There are only maxi-mum flow ratings from the A and B work



Are all functions slow, or only one function? Details will help with troubleshooting logic.

Use the schematic to sort out common pump feed lines, application sub-circuits and common tank returns.


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ports to the cylinder. Checking those flow ratings would require flow meters and a fair amount of time to install them. The technician decides to check the electrical signal to the solenoids, as seen on page 46. The directional valves are proportional valves that can vary the flow rate to the cylinder, depending on how far the operator moves the control stick. This means that the valve solenoids receive a signal that is more sophisticated than just an on-off voltage. The best way to test the drive signal as specified in the machine manual is to measure the range of dc current on one of the two conductors for each solenoid. The manual specifies that the normal solenoid current for the range of motion on the operator’s control stick is 0 to 800 mA. The test for each solenoid doesn’t take long, and it is soon confirmed that the electronics and electrical system for the valve is working fine. The technician had assumed that if for some reason, the machine’s electronic controller was only sending up to, say, 400 mA maximum to each solenoid, that the problem of a slow cylinder would be due to a proportional directional valve that was not being driven correctly to achieve the full and normal flow rate. One last external examination of that valve bank reveals a clue that the technician hadn’t noticed yet. There was a bit of scuffing on the jam nut for one of the two shock relief valves in the bucket curl section. It appeared as though just one of the two shock relief valves had been adjusted by someone. The technician wondered if this change could have anything to do with with the slow bucket curl in both directions. It didn’t seem likely, but the matter still needed investigation.

There are important details in the symbols that can help a troubleshooter.


50 FLUID POWER WORLD 3 • 2016 www.fluidpowerworld.com 3 • 2016 FLUID POWER WORLD 51

The technician called the operator and asked if anyone had worked on the unit or made any changes to valve settings in recent days. The operator told the technician a story about needing to hoist some concrete blocks across a ditch. The lifting chain had been at-tached to the bucket teeth with the bucket curled all the way inward. The operator would leave the bucket curl valve in neutral (A and B ports blocked) and just lift the boom and swing the block across the ditch. Some of the blocks were so heavy that the bucket cylinder moved inwards during the lifting. The chain would then fall off the teeth and the block would drop. The operator had been told by another operator of a similar machine that he could just increase the setting on that one shock relief valve by a full turn or two, and that the bucket would then stay in position and not curl outward while lifting. The technician realized that this danger-ous action by the operator was subjecting the bucket curl’s sub-circuit to harsh treatment, but still couldn’t quite understand how this one valve adjustment might have caused the prob-lem of a slow bucket curl in both directions of cylinder movement. The technician followed a procedure in the manual to reset the shock

Components on parallel paths back to tank could divert flow when faulty.

Style of piston seal. The parts manual may have helpful clues.




Know the function of each component and when it should be open or closed

relief valve to the correct setting and kept on thinking. While looking at the extended rod of the bucket curl cylinder, the techni-cian began to wonder if she was seeing a slight bend in that rod. After confirming with a straight edge that the rod for the bucket curl cylinder was indeed bent, the technician realized what had most likely occurred. The shock relief valve that the operator had tampered with was the one for the “A” port, protecting the blind (base) end of the cylinder. While lift-ing with the bucket locked in position, the excess weight was essentially forcing the piston against a body of trapped fluid in the cylinder. With the rod fully extended, and the shock relief taken out of action due to the operator adjustment, the excess weight was flexing the bucket and making the cylinder rod bend. It was now permanently bent, which was accounting for an unusual level of friction for the cylinder as the rod was moved in either direction.

Repair and further analysisThe repair solution was simple—install a new cylinder and note with a bold warning on the work order that an important valve, a shock relief valve, had been adjusted up-ward from its safe and proper setting by an operator, resulting in a bent cylinder rod. With the machine verified to be back in normal working order on the job site, the next logical step for a machine owner and the technician is to think of what might pre-vent this problem in the future. In this case, the options included dealing with opera-tor work procedures and policies, and/or asking the machine manufacturer to install tamper proof shock relief valves. Troubleshooting is our primary subject in this article, so let’s continue with an analysis of the procedures followed. What the technician did correctly was to avoid any rushed component swap-ping. She also avoided conducting time consuming tests until she had exhausted all possible simple causes, and had visually scoured the hydraulic system for external clues. A close look at adjustment screws might reveal a clue.

If anything, the technician could have spent even more time talking to the opera-tor back at the beginning, to try to get the full story about everything that had recently happened. There is of course, no guarantee that the operator would have shared all of the details up front. The technician took the time to study the schematic carefully and interpret the circuit features. She anticipated where


FluiDyne 3-16_FPW.indd 53 3/14/16 10:46 AM



internal leakage paths could occur, and used logic to determine that multiple simultaneous faults were not as likely as a single, simpler cause. With the boom and stick cylinders op-erating at normal speed, even when used in combination, the pump was an unlikely suspect component. If the complaint was that all machine functions were operating slower than normal, the pump would have made it onto the suspect list. Achieving “battle readiness”

for next timeAs mentioned earlier, troubleshooting activities can use up a lot of time. This is especially the case when diagnostic instruments such as flow meters have to be installed. Half the battle in efficient and effective troubleshooting is knowing exactly what “normal” is. Regular maintenance checks should include cylinder cycle times, so that a complaint of a slow cylinder can be under-stood in the context of optimum machine performance. When a new machine model is brought under a technician’s care, she might choose to measure the thread length on the adjustable spool travel stops, or the number of turns outward from high-est (closed off) setting of the shock relief valves. Observing the machine running normally on the job site can yield valu-able references for detecting the less than optimal performance that may precede a breakdown. Taking careful note of normal pressure values, component temperatures and the normal whistling sounds of fluid passing through valve components can help locate an important clue when the machine be-gins to malfunction. As is so often the case, a sudden malfunction can have a simple cause. It is possible for that simple cause to be buried deep inside a pump or a valve bank. How-ever, with keen investigation, observation and analysis skills, a technician will be able to find the simple causes that are accessible from the outside of the system. FPW

Machine abuse by operator can create troubleshooting challenges, and safety issues too!

Use the schematic to aid in fault analysis.


Discuss This

Lessons Learned: • Get a complete story from the operator • Confirm the fault • Look for any obvious external clues (leaks, discolored paint, etc.) • Consult the schematic to plan tests logically • Avoid guesswork (part swapping, experimental settings changes) • Keep looking for simple causes • Verify the repair • Observe and record normal operation • Improve maintenance and battle plan

CD Industrial Group Inc.carldyke.comLunchBoxSessions.com

Mobile Troubleshooting Part 2_Vs5 MG.MD.indd 54 3/16/16 10:31 AM

G A U G E S

The lowdown on


Josh CosfordContributing Editor

What is a gauge? A gauge is any device designed to measure the intensity of a particular

type of energy or quality. A light meter is a device that converts photon energy into electrical current

so it can measure the intensity of light, for example. Gauges need not be so evolved as the photovoltaic cell

in a light meter; however, a rain gauge is just an open tube with markings on it to measure how much rain has

fallen since the last time you looked at it. In the fluid power world, we typically have three major

criteria worth measuring: pressure, flow and temperature. There are a few smaller qualities we quantify, but these three provide the most accurate

snapshot of the health and performance of your hydraulic or pneumatic system. And in measuring pressure, flow and temperature, there are also three levels of accuracy customarily used, which I will describe as I discuss each measurement criterion.

Accurately measuring pressure, flow and temperature is critical in any

fluid power system, so knowing which gauge is best suited

to your application is key to safe, efficient design.

gauges

Hydraulic applications commonly use 2.5-in., bottom mount type or panel mount gauges, configured with ¼-in. NPT male ports. This stainless-steel design from Noshok is available from 0 to 100,000 psi in 11⁄2, 21⁄2, 4 and 6-in. gauge sizes.

FPW_Gauges 3-16_Vs4 MG.MD.indd 55 3/15/16 12:24 PM

G A U G E S

Of utmost importance: pressurePressure is the essence of fluid power. The ability to condense matter and move it around is how hydraulic and pneumatic systems are capable of such wonderful things. Most fluid power systems have at least one pressure gauge, while others can have dozens of locations with test points where a pressure gauge can be at-tached while the machine is running. Pressure is measured in both hydrau-lic and pneumatic systems with the same type of pressure gauge. The bourdon tube pressure gauge is the most common type used to measure fluid pressure because it is reliable, inexpensive and relatively simple. The bourdon tube is a curved tube closed at one end, which is attached to a spring-loaded mechanism that is itself attached to the gauge’s needle. The port of the gauge is attached to the loca-tion in the system where you’re measur-ing pressure. As pressure increases within the bourdon tube, the metal tube starts to straighten, and as it does, it tugs on the lever attached to the needle. The magni-tude of straightening, and the movement of the gauge are highly precise, and each gauge is calibrated when manufactured. Pressure gauges are highly reliable, but can degrade over time, especially with pressure spikes.


Design engineers need to be able to selectively control how safe exhaust operates, on vacuum cups for example, where damage can occur if the vacuum is suddenly lost.

Illustration (and model above) show how Bourdon tube pressure gauges work, with a curved tube closed at one end, which is attached to a spring-loaded mechanism that is attached to the gauge’s needle. Image courtesy of Noshok

Test point quick couplers are permanently installed male fittings, located in key locations around the hydraulic system. The gauge adapter is also permanently attached to the gauge, and the female port mates to the male test point. Images courtesy of Brennan Industries

The quality of the gauge plays a role in its accuracy and reliability. A glycerine-filled gauge, for example, uses liquid glycerin to act as a fluid damper, which can not only dampen pressure spikes, but reduces the tendency of the needle to vibrate or jump across the dial. Should toxic or corrosive fluid require measurement, or if temperature extremes are constant, diaphragm seals can be used to isolate the gauge from the fluid of the system. The system fluid pushes on the diaphragm, and the diaphragm pushes on the transmitting fluid, actuating the pressure gauge. Fluid

power systems rarely operate with fluids so exotic as to require diaphragm seals, so I won’t discuss them further.

A pressure gauge for most applicationsBy far the most widely used pressure gauge for hydraulics is the 2.5-in. bottom mount type. A close second in popularity is the same 2.5-in. dial size gauge, but with back mount, also known as panel mount. Each of these is most often configured with ¼-in. NPT male ports, and although any port is available, they are usually special order items. It goes without saying that an O-ring thread would be preferred, but the confusing popularity of NPT is a discussion for another day. Regardless, the 2.5-in. dial gauge is at the upper range of accuracy for pressure gauges, and is used to express a relatively exact number.


G A U G E S


Tobefair,thethreadisoftennotimportant,becauseNPTgaugesarepermanentlyinstalledandusuallydon’tleak,orthegaugesareaddedtoatestpointadapter.Atestpointisaspecialtypeofquickcouplercapableofbeingconnectedtothesystemunderhighpressure.Thetestpointsarepermanentlyinstalledmalefittings,locatedinkeylocationsaroundthehydraulicsystem.Thegaugeadapterisalsopermanentlyattachedtothegauge,andthefemaleportmatestothemaletestpoint.Theadvantageoftestpointsisareductionincost,astestpointscanbepurchasedforaquarterofthecostofindividualgauges.Permanentlyinstalledpressuregaugesarepronetofatigueandfailure,sotestpointsavoidthisissueatthesacrificeofconvenience. Ifconvenienceisdesiredandbudgetislessofaconcern,permanentlyinstalledgaugescanbeequippedwithsnubbervalves.Gaugeisolatorscanalsobeaddedtoimprovereliability.Thesnubbervalveisusuallyjustanadapterfittingwithanorificedesignedtodampenpressurespikesorhydraulichammer.Agaugeisolatorisashut-offvalvedesignedtoblockfluidenteringthegaugeentirely.Whenapressurereadingisrequired,thevalveisopened,themeasurementisobserved,andthenthevalveclosedagain.Thissolutionprovidestheultimateinreliabilityandconvenience,butasyoucanimagine,thecostcanbeprohibitive. Pneumaticpressuregaugesarelessexpensiveandusuallypermanentlyinstalled.Themeasurementrangeisrarelymorethan150psi,sotheirdialfacesaresmaller,oftenonly1.5to2.0in.Thesmallergaugesalsohavesmallerports,usually1⁄8in.NPT.Thismakesthemeasytomountdirectlytovalvesandcomponents.Pressureregulators,forexample,arenotmuchgoodwithoutaninstalledpressuregauge,asplayingguessworkwiththepressuresettingiscounterproductive. Flow meters: a window into the systemPressureisusuallytheonlycriteriameasuredinpneumaticsystems,butflowandtemperatureareimportantforobservationinhydraulicsystems.Becausewecannotseewhatishappeninginsidethecomponentsandconduitsofahydraulicsystem,itisadvantageoustomeasureflowwithadedicateddevice.Theinlinehydraulicflowmeterusestheflowforcesagainstaspring-loadedmagneticorificetomovetheneedledownthefaceofthedial.Moreflowequalsmorepressureagainsttheorifice,andthefartherthemagnetdragstheneedledownthegaugeface. Althoughnothighlyaccurate,becausesomanyfactorscontributetothepressurepushingontheorifice,theinlineflowmeterprovidesyouwithasolidrepresentationofwhat’shappeninginthesystem.Iflessaccuracyisrequired,asimpleflowindicatorcouldsavecost.Asolidmetalbodywithaportedwindowcontainingeitheraflapperorpaddle-wheelwillshowyouthatflowexists.Thisishelpfulwhentroubleshooting,especiallywhentherearemanysub-circuitsinthesystem,althoughtheseindicatorsaremorepopularintheprocessindustryratherthanfluidpower.

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G A U G E S

Maintain system health with proper temperaturesA healthy hydraulic system enjoys a “Goldilocks zone” of warmth, where the oil is warm enough to flow well, but not so hot as to oxidize or lose lubricity. Measuring temperature in a hydraulic system is most common with the reservoir-mounted level and tempera-ture gauge. A thermometer is mounted into the glass of the level gauge, but represents the general thermal health of the system, telling you nothing of where heat is generated, just that it is hot. Just like the 2.5-in. dial pressure gauge, the same unit is available for measuring temperature, but with a tiny probe that sticks out the bottom past the port thread. The probe must extend into an area of flow, or it will provide an inaccurate measurement of heat. This type of inline mounting can give you readings at vari-ous locations in the system, which helps in troubleshooting. A thermometer in the return line of the main system’s relief valve is a good indication that it could be jammed open by contamination, for example. In pneumatic systems, temperature is rarely monitored, except perhaps at the compres-sor or dryer stages, as heat related to pressure drop is less dramatic than it is with hydraulics. Know which accuracy level you needEach fluid condition can be measured accu-rately, generally or inexactly. The dial gauge can be purchased in up to 8-in. or larger dial face, which will have finer graduations, and a more accurate view of pressure or temperature. High quality gauges are accurate within 0.5% or better, but even economical gauges can achieve accuracy within 2%, full scale. When the cost isn’t justified for a high accuracy dial gauge, a general measurement of pressure, flow or temp-erature may suffice. The paddle-wheel flow indicator can show the general velocity of fluid passing through it by observing the speed of the spinning wheel. Inexpensive


differential pressure gauges on hydraulic filter assemblies are sometimes a small dial showing gradients of green, yellow and red to represent how clogged the filter element is. If the needle rests in the green zone, the filter is free-flowing. If the needle makes its way to the yellow zone, the trapped contamination is starting to create pressure drop through the filter, warning you to change the element soon. Should the needle reach red, you are now risking the bypass valve opening in the filter assembly, at which point your filter is no longer filtering at all. The “go, no go” option of pressure, flow or temperature measurement is the lowest level of accuracy. Indicators simply tell you that a condition does or does not exist. A pressure indicator can be found in filter assemblies as well, and will simply pop-up when a pre-set pressure is reached. The pop-up indicates you need to change your filter soon. The inline flow indicator can simply be a spring-loaded flapper that shows that flow exists or does not exist.

Temperature indicators are less popular, at least in the analog sense. Electrical tem-perature warning lights are popular, but fall outside the realm of analog discussion here. In any event, electronic pressure, flow and temperature measurement is exponentially more accurate than analog dials, but that is a discussion for another day. FPW


Discuss This

This Hedland inline hydraulic flow meter uses the flow forces against a spring-loaded magnetic orifice to move the needle down the face of the dial. Image courtesy of Badger Meter

Illustration of the inner workings of Hedland flow meter Image courtesy of Badger Meter


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This year, with green energy and environmental matters hotter

than ever, 2016 is looking to be a big year for the conference. Energy

professionals will be meeting May 2–5 to share ideas, strategies and

knowledge about offshore resources.

Sponsored by 13 industry organizations and societies that work collectively to develop the technical program, OTC gives attendees access to leading-edge technical information and the industry’s largest equipment exhibition. These organizations also use revenue to provide many other important programs for its members, such as training and technical journals.


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I N D U S T R I A L H Y D R A U L I C S


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Accumulators Inc. .........................................................6224Alfa Laval Inc. ................................................................2779All Seals Inc. ..................................................................8525API Heat Transfer ..........................................................3900ASCO Numatics .............................................................5817Ashcroft Inc. ..................................................................4056Atlas CopCo ...................................................................3169Balluff Inc ......................................................................4517BASF Plc .........................................................................2341Baumer Group ..............................................................7629Blacoh Fluid Control, Inc. ..............................................7543Bonfiglioli USA ...............................................................327Bosch Rexroth Corp. .....................................................4416BVA Hydraulics ..............................................................6625CEJN North America......................................................1277Continental ContiTech ...................................................8445Dynapar .........................................................................3567Dynex/Rivett Inc. ...........................................................1501Eaton .............................................................................3517ERIKS Seals & Plastics, Inc. ............................................2479Evonik Corporation .......................................................9733Famic Technologies Inc. ................................................5525Festo Corporation .........................................................6009Flaretite .........................................................................8622FLUORTEN S.r.l. .............................................................7707Fox Srl ............................................................................11909Freudenberg Sealing Technologies ...............................2923G.W. Lisk Company ........................................................4571Gardner Denver Inc. ......................................................5849Gates Corporation .........................................................4077GEA Heat Exchangers ....................................................656Gleason Reel .................................................................4063GP:50 .............................................................................2221GS-Hydro OY ..................................................................4117Hannay Reels Inc ...........................................................6237Haskel International, Inc. ..............................................2765HAWE Hydraulik ............................................................3801Hengli America ..............................................................13307Houghton International ................................................3666Hunger Hydraulics CC Ltd .............................................10138HYDAC Technology Corp. ..............................................2575Hydradyne LLC ..............................................................2900Hydraquip Custom Systems, Inc ...................................1351Hydraquip, Inc. ..............................................................1351Hydratech Industries .....................................................5465Hydraulics International, Inc. ........................................2406Hy-Lok USA ....................................................................1209IC-Fluid Power Inc .........................................................10045igus Gmbh .....................................................................7020IMI Precision Engineering .............................................2441Ingersoll Rand ...............................................................13451

Innovative Fluid Power .................................................7222Kaeser Compressors, Inc. ..............................................8133Kaydon Custom Filtration..............................................1301Kluber Lubrication .........................................................2923Kobelco Compressors America, Inc. .............................1801Kocsis Technologies, Inc. ...............................................6115Lexair Inc .......................................................................6116Lillbacka USA .................................................................6024Magnetek ......................................................................9356Magnetrol International ...............................................1305Manuli Hydraulics .........................................................7009MFP Seals (A Div. of Martin Fluid Power) .....................3580Midwest Hose & Specialty Inc. .....................................2671Moog .............................................................................3903MSO Seals & Gaskets ....................................................8563MTS Systems Corp. Sensors Division ............................7413NOSHOK INC .................................................................5700NRP-Jones, LLC ..............................................................1908Oerlikon Fairfield ...........................................................412PacSeal Hydraulics, Inc. .................................................5520PANOLIN America Inc. ...................................................5063Parker Hannifin Corporation .........................................4340Pennecon Energy Hydraulic Systems ............................1633PH Hydraulics & Engineeering Pte Ltd ..........................4765Pneumatic and Hydraulic Company LLC .......................5421Rota Engineering Ltd .....................................................2641Rotork Controls .............................................................1171Ryco Hydraulics .............................................................5771SC Hydraulic Engineering Corp. ....................................5071Smalley Steel Ring Co. ...................................................3704Spir Star .........................................................................3605SPX Flow ........................................................................5505Staubli Corp. ..................................................................9873Stucchi USA Inc. ............................................................8552Sunsource......................................................................6130Swagelok .......................................................................1641Techflex, Inc...................................................................8821Texas Hydraulics Inc ......................................................312The Lee Company .........................................................3409Trelleborg Engineered Products ...................................5541Trelleborg Fluid Handling Solutions ..............................5541Tube-Mac Piping Technologies Ltd. ..............................1371U.S. Tsubaki Power Transmission ..................................6213Voith Turbo, Inc. ............................................................4517Wandfluh of America ....................................................1351Webco Industries, Inc. ..................................................3579Wichita Clutch ...............................................................1063WIKA Instrument, LP .....................................................3005Winters Instruments .....................................................1281Womack Machine Supply Co. .......................................5216

E X H I B I T O R L I S T

OTC 2015 Fluid Power Companies ...............................Booth OTC 2015 Fluid Power Companies ...............................Booth


62 FLUID POWER WORLD 3 • 2016 www.fluidpowerworld.com 3 • 2016 FLUID POWER WORLD 63



Discuss This

Additionally,attendeeshavethechancetoconnectwithvaluablenewprofessionalcontactsfromaroundtheworld.Withmorethan90,000professionalsfrom130+coun-triesinattendance,networkingopportunitiesabound.TheOTCoffersthechancetosetupclientmeetings,businessproposalsandcompanytraining.

Newfor2016,OTCislaunchingseveraltrain-ingcourses.Eachcoursewillbehostedbyoneoftheconference’svarioussponsoringsocieties.Topicswillincludethefollowing: •ASMECodeDesignRequirementsfor HP/HTWellHeadComponents •Deep-waterRiserEngineering •MarineBroadbandTechnologies: TheoryandPractice •ModernWellDesign •RecognizingCatastrophicIncident WarningSigns

TheconferencewillalsoholdaUniversityR&DShowcase,DistinguishedAchievementAwardsluncheon,SpotlightonNewTech-nologypresentationandTheNextWave,aprogramforyoungprofessionalsthatwilladdresswhatisneededtoobtainajobinthesenewmarketsandhowtobecomeadrivingforceforthefutureoftheindustry.And,forsomeR&RfromtheR&D,theconferencewillbehostingaNightattheBallparkeventtoseetheHoustonAstrosplaytheMinnesotaTwinsatMinuteMaidPark. FPW

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Because of its programmatic flexibility, the EVC multi-function

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AD INDEX

Anchor Fluid Power .........................19AutomationDirect .............................1AVENTICS Corp. ...............................15Brennan Industries, Inc. ....................5C.matic ............................................26Camozzi Pneumatics Inc. ................62CD Industrial Group ........................57Clippard Instrument Laboratory, Inc. ...........................BCEaton Hydraulics .............................49FABCO-AIR, Inc. ...............................13Flaretite, Inc. ...................................62Flow Ezy Filters, Inc. ........................37Fluid Power Tech Conference .........27FluiDyne Fluid Power ......................53Gerdau Special Steel N.A. .................3Hengli America ..................................7Holmbury, Inc. ................................IBCHy-Pro Filtration ..............................50Hydra-Mount Corporation ..............26 HydraForce ........................................9

IC-Fluid Power, Inc. ..........................23Kawasaki Precision Machinery (U.S.A.) Inc. ...............59Kocsis Technologies, Inc. .................36MP Filtri USA Inc. ............................17Main Manufacturing Products ..........4Permco, Inc. ....................................41PHD Inc. ...........................................43Prince Manufacturing Corporation ................................31Servo Kinetics, Inc. ..........................25Super Swivels ....................................2Tompkins Industries, Inc. ............ IFC,4 Veljan Hydrair Inc. ...........................11

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LEADERSHIP TEAM

Co-Founder, VP SalesMike Emich508.446.1823 [email protected]@wtwh_memic

Co-Founder, Managing PartnerScott [email protected]@SMMcCafferty

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March 2016

www.fluidpowerworld.com

Safe packaging applications with pneumatics p.38 Mobile hydraulics troubleshooting, part 2 p.46 The lowdown on gauges p.55

PAGE 32

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Fluid Power World March 2016

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