Fluid Power World August 2015

August 2015

www.fluidpowerworld.com

Hydraulic press safety is vital in automotive manufacturing p.44 New environments challenge pneumatic cylinders p.50

PAGE 38

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F l u i d L i n e s

Fluid power, live and in person

Even the most casual reader of Fluid Power World would likely notice that training is an important part of the publication. Fluid power is a highly technical field, and continuing education is critical for engineers and designers of hydraulic and pneumatic systems. While we have a specific Training column that appears in each issue, a great deal of the editorial throughout focuses on bettering yourself as a fluid power professional and learning about the newest innovations in the field. But not all training happens on the printed page or online—sometimes it’s great to get out of the office and attend a meeting, conference or tradeshow to learn something new. So I’m happy to announce that we are launching the Fluid Power Technology Conference next year, with the inaugural event to be held at the famed Milwaukee School of Engineering. Our team here has multiple veterans of producing similar events in the past, so I know this new event will be a success. The Conference is being planned for June 21-22, 2016, and we’re hoping to have some great optional tours to places like the MSOE Fluid Power Institute laboratory and the Grohm-ann Museum of human industry and work. The Conference will feature keynote presentations, as well as down and dirty, how-to sessions and examination of the latest fluid power technology and componentry. Plus, we’ll have a small trade fair area, where you’ll be able to network with other industry professionals and talk with the major component manufacturers. We’re excited about starting this new avenue of fluid power training for you, and I hope you’ll mark your calendar now for next June. Milwaukee’s a great all-American city, and summertime there is just fantastic, with myriad festivals and concerts. Please stay tuned for further details and registration information. We look forward to seeing you in person, soon.

2 FLUID POWER WORLD 8 • 2015 www.fluidpowerworld.com

Paul J. HeneyEditorial Director

[email protected]

On Twitter @DW_Editor

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HOW DO I KNOW IF I’M TALKING TO AN ENGINEER OR A SALESMAN?

Ask Smalley. We have nothing against sales people. But when it comes to differentiating Inconel from Elgiloy or overcoming dimensional variations within a complex assembly, wouldn’t you rather work with an engineer?

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THE ENGINEER’S CHOICE™

HOW DO I KNOWIF I’M TALKING TO AN ENGINEER OR A SALESMAN?

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THE ENGINEER’S CHOICE™

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AUGUST 2015 • vol 2 no 4 • www.fluidpowerworld.com

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EDITORIAL

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

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Senior EditorMary [email protected]@dw_marygannon

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Associate EditorMike [email protected]@wtwh_Michael

Contributing EditorJosh Cosford@FluidPowerTips

Director, Creative ServicesMark Rook [email protected]@wtwh_graphics

Visual Design ManagerMatthew Claney [email protected]@wtwh_designer

Graphic Designer/Production CoordinatorMargaret [email protected]@wtwh_meg

Graphic Designer InternErin [email protected]

Traffic ManagerMary Heideloff [email protected]

Director, Audience DevelopmentBruce Sprague [email protected]

SALES

VP Sales

Todd Tidmore

512.626.8263

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408.769.1188

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Jim Powers

312.925.7793

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@wtwh_jennifer

4 FLUID POWER WORLD 8 • 2015

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WHAT DOES TRUST MEAN TO YOU? Tell us at: www.munciepower.com/trust

In a day where service and support is too often outsourced or pushed downstream, our team is ready to respond to your call. With hundreds of years in combined experience and the strongest training program in our industry, you can count on us to help. At Muncie, we understand that we’re building much more than hydraulic components. We are building trust. MUNCIE POWER PRODUCTS

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8


ON THE COVER Hydraulic seals must go above and beyond leakage prevention in offshore applications. Photo credit istockphoto.com, courtesy of Trelleborg Sealing Solutions.

38

D E PA R T M E N T S

02 Editorial 08 Research & Development

12 Association Watch

16 Distributor Update

20 EnergyEfficiency

22 Design Notes

26 Fundamentals 28 Maintenance

32 Training

34 Safety

58 Component Focus

59 Product World

60 Ad Index

44

50

Aug

ust 2

015 Contents | v o l 2 n o 4 | f l u i d p o w e r w o r l d . c o m

32

F E AT U R E S

OFFSHORE HYDRAULICSSuccessful offshore sealing

Hydraulic systems in marine environments require a complex combination of

specialized seals. Understanding the different materials and styles is critical to a

safe, successful design.

INDUSTRIAL HYDRAULICSHydraulic press safety is vital in

automotive manufacturingSafe environments rely on a complex

system of components, from redundant con-trol valves to rod locks and light curtains

to linear position transducers, and more.

PNEUMATICSNew environments challenge

pneumatic cylindersExtreme environments have forced

pneumatic cylinders to adapt. Here’s a look at some that meet these challenges.

Contents_FPW 8-15_Vs2 MG.indd 6 7/29/15 2:57 PM

Forged Strong to LaSt Long. From continuous casters and melt shops to hot and cold mills to galvanizing lines and coke plants, Yates Cylinders are working hard in all areas of the steel industry—designed and manufactured to stand up to the rigorous environment these cylinders must endure every day.

High heat, debris and dirt are some of the factors our series of Mill Duty, Tie Rod and Round Body Welded cylinders overpower daily in a steel mill.

Yates works closely with many companies to help solve their cylinder failures, first determining the cause and in many cases recommending upgrades for a rebuilt cylinder. This process not only eliminates the original problem, it also offers an extended life for the cylinder at a fraction of the cost of a new one.

With three regional locations offering full service capabilities (engineering, welding machining, grinding and assembly) and around-the-clock service, Yates is one of the largest and most complete cylinder manufacturing and repair companies in the country.

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RESEARCH & DEVELOPMENT


Setting The Standard For Solar Storage

Lately, to talk about the Center for Compact and Efficient Fluid Power (CCEFP) is to talk specifically about the dollars and cents of the Center’s future. Its research and education programs and their impact on the fluid power industry are all worthy, but ultimately, supplemental conversation points. With the National Science Foundation’s (NSF) funding of the

CCEFP already decreasing and set to be finished by the end of March 2016, this is understandable. Half of the CCEFP’s budget comes from the NSF. But during a recent CCEFP webcast, the tone was optimistic. University of Minnesota professor and CCEFP Director Kim Stelson said that there were, “lean times ahead,” but that the organization will be okay. By

placing a heavy focus on unprecedented collaboration between the National Fluid Power Association (NFPA) and the CCEFP, both organizations see complete sustainability in the next few years.

Months after launching a new giving and recognition society within the NFPA Education and Technology Foundation to increase support for fluid power education

CCEFP Webcast: Lean times, but bright future, ahead

RESEARCH & DEVELOPMENT Mike Santora • Associate Editor

CCEFP Sustainability Strategy

• Industry consortium pool funds precompetitive research projects

• Universities cap indirect charges at 10% to help attract pooled funding

• Associated research projects from both government and industry are championed by individual faculty• Industry can define project direction and control IP

• Large multi-site blockgrants support additional

research• Shoulders some of the

administrative costs ofoperating the Center

• Industry is pleased due to added leverage• Universities are pleased due to indirect support

IND

UST

RY

ASS

OCI

ATE

D

GO

VER

NM

ENT

SUSTAINABILITY

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1 0 FLUID POWER WORLD 8 • 2015 www.fluidpowerworld.com www.fluidpowerworld.com 8 • 2015 FLUID POWER WORLD 1 1

RESEARCH & DEVELOPMENT

and research, the NFPA and the CCEFP have formed a collaborative, staffing plan to provide administrative support for those activities and to better promote the fluid power industry.

“There is a lot of alignment between the activities of the CCEFP and the market-ing and education objectives of the NFPA,” said Eric Lanke, NFPA CEO. “Fluid power research performed by CCEFP universi-ties not only develops additional teaching resources and connects more students to our industry, it helps to expand fluid

power’s innovation capacity. Promoting CCEFP research objectives and outcomes can therefore improve the image of our technology in the minds of our customers and of our industry in the minds of aspir-ing engineers.”

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The staffing plan has been designed to combine the inherent strengths and resources of both organizations. The CCEFP plans to increase its focus on research, education and a more integrated connec-tion to the better resourced marketing and communication functions of the NFPA.

“It’s truly a win-win for both organiza-tions,” said Stelson. “As the Center transi-tions away from NSF funding, this adminis-trative collaboration with the NFPA will help us both broaden the industry’s awareness of our activities and deepen our impact

on its behalf. I’m really excited about the added potential this collaboration brings to both organizations.” FPW

Center for Compact and Efficient Fluid Power ccefp.org

and other engineering topics atwww.engineeringexchange.com

Discuss This

There is a lot of alignment between the activities of the CCEFP and the marketing and education objectives of the NFPA.

FPW_Research 8-15_ Vs6 MG.MD.indd 10 7/29/15 1:24 PM

To l l F r e e : 8 8 8 - 3 3 1 - 1 5 2 3 • w w w . b r e n n a n i n c . c o m

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ASSOCIATION WATCHASSOCIATION WATCH


The NFPA is cleaning out the garage they call NFPA.com. It’s a big process, but they think you will appreciate the result when they’re done.

NFPA.com has long been the site for information they make available to members, prospective members, people who want to know about fluid power, purchasers of standards and others.

The NFPA recently said, “Just like most of our garages, we use it for everything, and it gets junked up over time. But unlike a garage, the door to our website is open, the lights are on 24/7, and our clutter is visible. It would be wrong to set a fire and wait for the insurance check. So with brooms and dustpans in hand, here’s what we’re going to do…” The following list outlines NFPA strategies for streamlining their site:

• Take content out of the one-site clutter and organize across multiple sites, each focused on a specific content or audience area to help drive greater visibility.• Establish clear and logical navigation linkages among the sites.• Create a consistent look and feel so users know they’re on an NFPA site without needing to see the logo.• Where appropriate, create online networking communities to extend the value of networking from in-person meetings to the web.

• Ensure all sites are mobile-friendly, and of course…• Get rid of old junk!

The NFPA has learned from some early experiments. One of its first clean-up efforts can be seen at NFPA News (news.nfpahub.com). The NFPA said it doesn’t entirely have the look and feel they are planning for the long haul, but they’re leaving it as is for now. They have used NFPA News to start breaking down the silo walls, with multiple staff using WordPress to contribute content that gets published to the news site.

Two New WebsitesIn April and May they launched two new sites:

1 Events: nfpahub.com/events—This site serves as the main entry point for registration and information on all conferences, regional meetings, trade show activities and webinars.

2 Standards Development: nfpahub.com/standards—This site serves as the online workspace for standards development committees. Committee members can share and mark up documents, add comments, and vote and track ballots, building efficiency into the development process for everyone.

NFPA websites—What’s going on over there?

Edited by: Mike Santora • Associate Editor

FPW Dept Assoc Watch 8-15_Vs7 MG.MD.indd 12 7/30/15 3:38 PM

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ASSOCIATION WATCH

8 • 2015 FLUID POWER WORLD 15

What’s Next

1 Stats/Reports: nfpahub.com/stats will be the main point of entry for all NFPA statistical services program information, including Confidential Shipment Statistics Report, forecast reports and the Electronic Statistical Toolkit. The site is expected to launch in September.

2 Fluid Power Design Blog: This site is planned for the end of 2015 and will be focused on promoting fluid power technology to external audiences (URL to be determined later). Content will come from members and will be focused on promoting the advantages of hydraulics and pneumatics through case examples and general guidance on how to design and maintain systems. Staff has begun working with the NFPA Pneumatics Council on some of these ideas.

3 Workforce/Careers: This summer, the process of planning for an overall web presence will begin. This new web presence will be aimed at promoting workforce development efforts, as well as connecting students, educators and industry as a community. The NFPA intends to complete planning and start building by the end of the year for a spring 2016 launch.

4 NFPA.com and NFPAFoundation.org: NFPA.com will be more focused on information about NFPA, the industry and membership. The Foundation site will go away, as content transfers to Workforce/Careers and NFPA.com. When the dust settles, the NFPA wants the look and feel to be consistent with the other web properties.

What’s the toughest issue in all of this? Getting NFPA.com with its many database-driven features and text-heavy pages trimmed down and moved effectively into WordPress. Hide the gas can and matches, and by this time next year, they said they should have it all done. Stay tuned. FPW

NFPAnfpa.com


Discuss This

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ASSOCIATION WATCH

Edited by: Mike Santora • Associate Editor

Foundation grant brings fluid power trainers to students in Texas

Angelina College in Lufkin, Texas, received a fluid power lab grant from the NFPA Education and Technology Foundation in July 2014. They used the funds to purchase three trainers—one hydraulic based and two pneumatic based. Each new learning system has a set of Learning Activ-ity Packets (LAPs) that include objectives, activities, skills and reviews designed to help students understand and demonstrate the different aspects of hydraulic and pneumatic systems. The activities and exercises are hands-on and help students develop a practical understanding of each topic.

Four fluid power courses used the new fluid power trainers in the spring 2015 semester at Angelina:• Advanced Hydraulics • Basic Fluid Power II—Pneumatics• Basic Fluid Power I-Hydraulics • Hydraulics, Fabrication & Repair

The courses included assignments and lab experiences that dem-onstrated the use of the new hydraulic and pneumatic learning systems. Altogether, 56 students registered for the classes.

The Fluid Power Laboratory Grant Program helps establish state-of-the-art training labs at qualifying educational institutions. Hundreds of budding engineers use these labs to study fluid power with the eventual goal of working in the fluid power industry after they graduate.

Grant applications are judged in a number of areas—whether the lab uses both hydraulics and pneumatics, student involvement, what new projects are initiated and the lab’s multiplier effect to create other relevant projects and curricula. Several schools have taken advantage of the lab grant program in the past few years.

Western Michigan University students are currently using the lab in the IME3840 Fluid Mechanics and Hydraulics class. It is anticipated that 130 students in five different undergraduate and graduate level classes will get hands-on experience with the lab each year. Milwaukee School

of Engineering (MSOE) used the grant for a new mecha-tronics/fluid power lab and many other schools are using the grant for similar purposes.

FPW

NFPAnfpa.com


DISTRIBUTOR UPDATE


Mary C. Gannon • Senior Editor

In the past, traditional distribution was simply that as a provider of a transaction—buying and reselling components. But in recent years, distributors have become an extension of an OEM’s engineering department, said Bill Tulloch, executive VP of Flodraulic Group. “What they need help with are solutions,” he said. “Particularly what we’re seeing in the industrial OEM marketplace, customers don’t have resident staff

engineers that are experts in fluid power technologies anymore. A lot of their engineers are mechanical or electrical, and they have a void in fluid power expertise.”

To that end, a successful distributor needs to understand its customers’ equipment and machinery and how that machinery functions in a greater application picture. So rather than just selling to a manufacturer of an excavator, for example, the distributor must fully understand who

is going to buy that equipment and how they are going to use it. This means a full understanding of not just fluid power but mechanical and electrical engineering and even down to ergonomics.

“Given all that, we now need to come to them with the full solution. More often than not, nowadays, that solution isn’t just fluid power,” Tulloch said. “A good industrial distributor now has to integrate multiple technologies. He may be bringing

The changing role of fluid power distributors

Fluid power distribution has changed a great deal over the years, with distributors serving more as system integrators and extensions of an OEM’s engineering department. Photo courtesy of RHM Flodraulic Group

MADE IN USA

TAKE A CLOSER LOOK

FPW_MFP_HH_AUG15A.indd 2 6/30/15 1:16 PMFPW 8-15_Distributor_Vs4 MG.MD.indd 16 7/29/15 1:36 PM

There is still room in the fluid power market for traditional distribution of buying and reselling components, like seen here.

to that customer pneumatics and hydraulics of course, but you’re bringing mechanical, you’re bringing electrical and controls. You have to understand PLCs and how that will control his equipment.” That being said, Tulloch stresses that there is room for everyone in the marketplace, whether it’s a small mom-and-pop business doing traditional distribution or large fluid power distributors that are more now system integrators.

The Internet, too, has changed the way a lot of distributors do business. For larger engineering-type distributors, it has allowed them to expand their product offerings by easily finding components to go into a complete system design. But, cautions Tulloch, “The engineering expertise that’s required can’t be replaced on the Internet.”

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www.fluidpowerworld.com 8 • 2015 FLUID POWER WORLD 1 9

For smaller distributors, it is necessary to have a good online presence, because users now have many more choices and often, underpriced choices. Having a good website and competitive pricing will keep customers returning to your company.

With some of these changes, Tulloch said that fluid power distributors have lost some market share to electrical and mechanical technologies, particularly in industrial applications like machine tools, plastics machinery and even small presses.

“The challenge to retain that and win some back, which we can do, is going to be keyed in on leveraging our existing capabilities, and that’s the power-to-size advantage that we have, and integrating

the controls and the electronics,” he said. “If we can do that, we have some compelling advantages. There’s no question we have a strong, strong challenge ahead of us going forward. The biggest thing is a strong understanding of electrical controls integration to leverage the finesse, the brains of electrical into the brute strength of the hydraulics side of the business.” FPW

This is an excerpt from a Technology Tuesdays Podcast with Bill Tulloch and Paul J. Heney, Editorial Director. Visit www.pneumatictips.com to hear the entire podcast.


Discuss This

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ENERGY EFFICIENCY

The knowledge gap

Ron Marshall • For the Compressed Air Challenge

A manufacturer of computer hard drives recently designed and installed a cutting edge compressed air system made up of premium efficiency components. The company installed six lubricant-free screw compressors, including one VSD. For air quality, premium efficiency heated blower-style dryers were selected and came equipped with dew point controls that reduced the power required for the regeneration cycles to only that which was necessary. The dryers were installed in parallel, with dual inlet filtration installed to minimize pressure drop. Compressed air piping was oversized so that there was minimal pressure differential across the complete system. All the compressors were controlled by a sophisticated sequencing control system that communicated with the compressors and attempted to select the correct units for the load.

Some significant funds were spent in putting this system together—yet the system did not run at optimum efficiency. Why? Because the designer of the system did not understand the concept of control gap when VSD compressors are installed in systems of multiple compressors.

The system was made up of five large 300-kW compressors and one 250-kW VSD. The 300-kW unit put out 1,530 cfm at full load. The 250-kW unit produced 1,375 cfmm, but only had a turndown of about 66%, or 915 cfm. Unfortunately, when this combination of sizes is put together, there will be a control gap equal to the difference in size between the fixed speed compressors and the VSD turndown. Any time the plant load is within the control gap, the VSD compressor will fight for control with the fixed speed units. Within this gap, with this combination of sizes, even a sophisticated controller gets confused.

During a plant visit, the system was observed to be within the control gap. Observation of the operating hours and the compressor history showed many hours of poor operation. The VSD was spending most of its time alternately ramping up to full speed, an inefficient point for VSD compressors, or rapidly ramping down to minimum speed, another less efficient point. While doing this, one fixed-speed compressor was loading and unloading rapidly. These inappropriate operations accelerate the wear and tear on the compressors and consume more energy. This is a symptom of control gap.

What the designer should have done was ensure the VSD compressor’s variable range—the difference between its full load

flow and minimum speed flow (915 cfm in this case)—was equal to or larger than the fixed speed base compressor’s (1,530 cfm). If these conditions exist, there is no control gap and the system will run optimally. Buyers must be aware of this sizing rule for VSDs. Unfortunately, some compressor salesmen do not know this rule or choose to ignore it to complete the sale. FPW

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DESIGN NOTES Mike Santora • Associate Editor

When Piab set out to create its new piFLOWp line of conveyors, it wanted to improve capacity and energy efficiency by moving vacuum pump technology away from the multi-ejector. The goal was to reduce lead time and cost through modularization of both the conveyor and pump. This meant a side mounted pump versus the old top mounted pump. It meant a new body design.

So how does one design a vacuum ejector for scalable capacity? How can you simplify and reduce cost in the vacuum ejector manufacturing without sacrificing quality?

Piab’s solution was integrating its COAX technology into the conveyor. With COAX cartridges, compressed air is injected into the cartridges through special nozzles. The force of the compressed air leads to a sharp drop in static pressure. The result is an ejector that requires low feed pressure and can handle fluctuations in pressure feed lines all within a smaller design. The design team also integrated both the silencer and the central exhaust in the

pump to create a better working environment. This design element simplified the disconnecting of the pump for service and maintenance.

Because the cartridges are smaller and more efficient than conventional ejectors, the design team was able to create a more flexible, modular and efficient vacuum system.

The cartridges provided the designers with three times more vacuum flow than a conventional system, while reducing energy consumption.

The design made it possible for the conveyor to give the user instant access to technical data, drawings and CAD files. This made the integration work much easier. Users could now change their configuration parameters online and see if the conveyor system fit into their application, instead of waiting weeks for a new drawing from the supplier. FPW

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When compressed air (1) passes through the nozzles (2), air is pulled through with the stream of compressed air. Suction will be generated at the opening of each stage (3), resulting in vacuum.

How to make a better vacuum conveyor

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24 FLUID POWER WORLD 8 • 2015 8 • 2015 FLUID POWER WORLD 25

DESIGN NOTES

Block coupler makes quick work of attachment change-out

Operator safety and failing hydraulic systems have led to a new

decompression block coupler from Holmbury. The HDB is designed for the quick change

of hydraulic attachments for skid steer, compact and backhoe loaders—as well as

compact utility vehicles. The decompression feature allows the operator to alleviate

trapped pressure allowing for quick and easy connection of various attachments.

Holmbury will launch the coupler at ICUEE in Louisville next month. It is rated for maximum operating pressures of 350 bar and temperatures ranging from -25 to 100° C. It offers flow rates of 86 lpm at 2 bar ∆P and decompression force of 130 Nm at 275 bar trapped pressure.

Traditional construction equipment attachment change-out is usually done through a standard set of flat face couplers that connect to the auxiliary hydraulics. Relieving trapped pressure on the attachment (auxiliary side) was achieved by using a connect-under-pressure coupler, such as the company’s HCP series. However, explained Matt Mulder, Holmbury president, “The challenge is how to alleviate trapped pressure on the machine side. The problem is that every skid steer loader

manufacturer has a different set of steps to relieve trapped pressure on the machine side. Unless this can be achieved, it is near impossible to connect an attachment because hydraulic

oil does not compress.” Holmbury developed the HDB when a major skid steer manufacturer was searching for a way to resolve a problem with its high-flow grapple attachment

application. Mulder said the skid steer was using a competitor’s block coupler, which decompresses

by pushing on the coupling. Due to the high-flow requirement, the rigidity of the hydraulic hose and the action of the grapple attachment, that block coupler decompression circuit was

opening inadvertently, causing the hydraulic system to fail and ultimately creating an

operator safety issue. With the new HDB, the

decompression valve cannot be inadvertently actuated during system operation. And it only


The HDB decompression block coupler from Holmbury alleviates trapped pressure, allowing for quick and easy connection of attachments on mobile machinery.




Discuss This

takes a few seconds to make the change, whereas the traditional way to decompress a skid steer loader system can take several minutes or longer due to the various steps required to relieve trapped pressure within the machine side.

Mulder said that the mounting pattern is a direct interchange with Faster’s 4BD4FH and Stucchi’s Saturn block coupler series, which is installed on the end of the boom arm on the skid steer loader. He added that Faster is the leader in the market, and until recently, was the only hydraulic quick coupling manufacturer to offer a connect-under-pressure block coupler. The decompression function of the Holmbury HDB is different in that there is an external valve stem (push or pull) that when actuated, opens the machine hydraulic circuit back to tank. This immediately takes trapped system pressure to 0 psi.

The Holmbury Decompression Block coupler features HQ series couplings with zinc nickel plating. It is fitted with Nitrile and PTFE seals. A pull activation feature prevents accidental system decompression.

All couplers are flat face and are designed to the 16028 Standard. Their low profile coupling design minimizes failures due to side-loading issues. They can be ordered in coupler arrangements of ½ in. for standard flow or ¾ in. for high flow applications. The case drain coupler is a standard 3⁄8 in. Finally, because the couplers allow for easy in-field replacement, they offer easy access for servicing of internal components and low cost. FPW

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FUNDAMENTALS

What is laminar flow?A fluid is unique in its capacity to be, well … fluid. A solid is solid

because its molecules enjoy staying put. A granite molecule joins hands

with its molecular friends, where they have to stare at each other for

millions, if not billions of years. Fluid molecules—remember that gases

and liquids are both fluids—are not so particular with whom they

associate, and they are perfectly happy with casual, fleeting relation-

ships. In fact, fluid molecules are always in motion, unless, and until,

they enter a solid state. Fluid molecules are easy to set in motion and

difficult to stop, which is why they are perfect for fluid power. It’s easy

to make a fluid “flow,” as it were.


As easily as fluid molecules move, they do have a preferred method of travel. If you work with dynamic pumps, laminar flow is a term you’re familiar with. Dynamic pump applications use the velocity of fluid (typically a liquid) to achieve work, which is why the term hydrodynamic is used. Because fluid velocity is as important as fluid pressure, a hydrodynamic system must consider the ease in which the fluid flows. Laminar flow describes this ease of flow, and it de-scribes how the desire of a fluid is to travel in parallel straight lines, whenever possible.

When fluid is prevented from this streamline flow, it expe-riences turbulence. Turbulence is the effect of fluid molecules bouncing, circling and reflecting in directions other than their desired path, and this turbulence is a huge energy waster. In hydrodynamic applications, the net effect of non-laminar flow is pressure drop. Bends, elbows, joints and even the surface finish of the conduit can reduce laminar flow and increase pressure drop. Reducing pressure drop in hydrodynamic ap-plications is a top consideration when designing applications because as much energy as possible should be conserved for useful work, rather than overcoming turbulence. But what about hydrostatic applications? Does the hydraulic industry need to consider the preservation of laminar flow at all costs? The easy answer is “it depends.” The difficult answer is going to require a little bit of math. Let’s consider two applications, one hydrodynamic and the other hydrostatic. Let’s take equal fluid horsepower output (100% efficiency for argument’s sake) of five, and we’ll split the energy up for each based on 120 psi hydrodynamic and 3,000 psi hydrostatic pressure:

120 psi x 71 gpm / 1,714 = 5 hp Hydrodynamic3,000 psi x 2.86 gpm / 1,714 = 5 hp Hydrostatic

Turbulent flow of fluid (top) versus laminar flow (bottom) can impact pressure drop and system efficiency in fluid power systems.

Fundamentals_FPW_8-15_Vs4 MG.MD.indd 26 7/30/15 3:51 PM



Discuss This

So in our fictional 5-hp examples, the hydrodynamic application can pump 71 gpm at our pressure limit, and the hydrodynamic application can achieve less than 3 gpm. Let us throw turbulence into the mix, and give each example 60 psi worth of pressure drop related to the poor plumbing of their systems. This 60-psi of pressure drop is the result of measuring pressure at the pump and then at our actuator. Our subsequent power calculation occurs at the actuator, not at the pump.

(120 psi – 60 psi) x 71 gpm / 1,714 = 2.5 hp Hydrodynamic

(3,000 psi – 60 psi) x 2.86 gpm / 1,714 = 4.9 hp Hydrostatic

So with the same pressure drop, the hydrodynamic application will lose half of its power potential compared to just a fraction for the hydrostatic application. So much of the work in a hydraulic application is through pressure, not flow, and the result is that laminar flow is nowhere near as important. The exception may be with massive flow systems, where a large amount of energy can be lost due to overcoming flow. However, even in those situations, the energy lost is still a small percentage, which is why pressure drop can be in the hundreds of psi and cause few worries. You won’t do any harm in trying to achieve laminar flow in your hydraulic system, but the effort in most cases isn’t worth the payoff. FPW

Fundamentals_FPW_8-15_Vs4 MG.MD.indd 27 7/30/15 3:54 PM

MAINTENANCE

Improper fluid levels in a hydraulic system can cause a number of difficult and sometimes even catastrophic failures. For example, having too much hydraulic fluid in the reservoir can cause the reservoir to overflow when a differential cylinder retracts. On the other hand, having too little fluid in the reservoir can introduce air into the system, causing cavitation and erratic motion. If left unchecked, air in a system can lead to foaming, which can result in unpredictable performance or even catastrophic machine failure. Without built-in safety precautions, this could leave machines to unexpectedly drop loads. Low oil levels can also reduce cooling and cause overheating, which reduces oil lubricity, reduces seal life and causes the system to run inefficiently. Noise is another byproduct of low oil, associated with pump cavitation and air in the lines. Installing some simple devices can prevent these types of problems and warn operators that a fluid level is too low or too high for the machine. Breather caps, column level indicators, fluid level indicators and viewports can be installed on tanks and throughout the system to maintain fluid and air ratios, while also giving operators a visual indication of how much fluid is in a system. As the first line of defense in a reservoir, breather caps help to equalize pressure in the reservoir by allowing free movement of air in and out of the reservoir as oil level rises and falls. They also feature a mesh filter to prevent contaminants from entering a system and

protect the filling point. This is particularly useful for cylinder functions, as hydraulic fluid volume fluctuates throughout the reservoir as cylinders extend and retract. This venting of airflow is one way to help prevent aeration and cavitation in the system. Because breather caps are critical in contamination prevention, they may need to be changed several times a year. High-end breather assemblies have some type of indicator to show that the filter element within them is clogged. To maintain their efficiency, it is imperative you don’t damage them, for example, by poking holes in the screens to speed up reservoir filling. Breather cap filters should have a minimum rating of at least 10 µm. Column and fluid level indicators and viewports are best viewed when a system is not running, as that will give you a true indication of how much fluid is in a system. This is because hot oil tends to expand. Column indicators are visual controls that accurately display the level of fluid running through a system. They should be located at each filler location and, like a temperature thermometer, show the oil level clearly on a gauge.



Maintain efficient machines with fluid indicators

Fluid level indicator caps, also called oil sight glass monitors or viewports, are small windows mounted to the outside of a reservoir marked to show upper and lower limits of fluid levels.

Located at each reservoir filler location, column indicators are visual controls that accurately display the level of fluid running through a system.

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MAINTENANCE

monitor the oil level inside reservoirs and other critical components. If levels are outside of the high and low marks, they can then investigate further where the problem is. All hydraulic systems should have at least two of these simple yet critical components to improve machine reliability. And not only can they extend oil and equipment life, they give maintenance personnel and machine operators a better handle on when they should consider a fluid change. Special thanks to Essentra Components, www.essentracomponents.com, for assistance with this article. FPW

They should be of a durable design that is resistant to shocks, vibration, solvents and oils with additives to ensure they are compatible with your application. Electronic indicators are also available, and can be equipped with analog electronic outputs to signal controllers or PLCs when oil level drops below a critical level. Fluid level indicator caps, oil sight glass monitors or viewports are similar to column level indicators, but in a much simpler format. They can be a simple round window featuring different types of glass with baffles to dampen fluid movement, or clear acrylic tubes. Both designs easily mount to the outside of the reservoir and have indicator marks to show upper and lower limits of fluid levels. These simple products help maintenance personnel quickly

Reservoir breather caps are the first line of defense in equalizing pressure and keeping contaminants out.

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TRAINING

Maintaining proper fluid levelsin the reservoir


The fluid level in a hydraulic and lube oil system reservoir is often overlooked—and taken for granted. Fluid flow

is the action in the hydraulic system that transfers the energy to perform the work. In addition, the fluid flow cools

system components, lubricates sliding and rotating surfaces in the system components and removes contaminants

from the system, all while sealing running clearances to minimize internal leakage.

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

Since fluid flow starts and ends at the reservoir, we must first understand the differences in the reservoirs used in a hydraulic system as compared to a lube oil system. In both systems, reservoir size is the key to operating an efficient system, by providing a steady supply of fluid, acting as a de-aerator and allowing the entrained air to rise and escape while solid contaminants settle to the bottom of the reservoir. This also makes it a fluid conditioner while providing a mounting platform for the pump(s).

Lube oil system reservoir: The volume of the oil reservoir should take into consideration the total feed to all bearings, gears, controls and other machine elements multiplied by the oil dwell time. For instance, allowing a 5-min dwell time for separation of entrained air and contaminants, a 1,000-gpm oil feed to bearings for a turbine-generator would call for a 5,000-gal reservoir.

Sizing the piping in the lube oil system: Pipe diameter must be large enough to avoid undue pressure drop in feed lines, to avoid backup in drain lines at the minimum oil temperature and to avoid cavitation in pump suction lines. Feed lines usually operate at 5 to 10 ft/sec velocity, drain lines 0.5 to 1.0 ft/sec and pump suction lines 3 to 5 ft/sec.

Hydraulic system reservoir: Sizing a hydraulic reservoir suggests that its volume (rule-of-thumb) should equal three times the rated output of the system’s fixed-displacement pump or mean

flow rate of its variable-displacement pump. This means a system using a 7-gpm pump should have a 35-gal reservoir. However, the substantial heat that can be generated within a hydraulic system should be considered when selecting the reservoir size. For example, large accumulators or cylinders that use large volumes of fluid or systems exposed to high ambient temperatures may require a larger reservoir unless they incorporate a heat exchanger.

Sizing the piping in a hydraulic system: The proper line size selection in the hydraulic system is critical to get maximum performance and life from the hydraulic system components.

The four basic line types in a hydraulic system are: 1. Pump suction,2. Return (Low pressure <100 psi),3. Medium pressure (500 to 2,000 psi),4. High pressure (2,100 to 5,000 psi). (Undersizing fluid lines will result in high-pressure losses and cause system overheating.)

Lines should be sized as follows: • Suction: 2 to 4 ft/sec • Return: 10 to 15 ft/sec • Medium pressure: 15 to 20 ft/sec • High pressure: 20 to 25 ft/sec

Oversizing lines increases the cost of the system.

FPW_Training 8-15_Vs3 MG.MD.indd 32 7/29/15 1:59 PM

www.fluidpowerworld.com 8 • 2015 FLUID POWER WORLD 33

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

Velocity through a line can be calculated with the formula:

Velocity (ft/sec) = gpm x 0.3288/Area

On extremely long lines, the pressure drop through the pressure and return lines must be accounted for. This helps to ensure sufficient pressure is available at the actuator.

The proper level in the reservoir ensures adequate space above the fluid level to give off trapped heat and non-condensable gases while reducing return line head pressure, allowing the fluid returning to flow at the proper feet per second. The proper level in the reservoir ensures that the Net Positive

This lubricating oil system for the oil and gas industry is much larger and complex than a hydraulic fluid reservoir. Photo courtesy of RHM Flodraulic Group

The 109-gal capacity hydraulic oil reservoir

(boxed in red) is fabricated by The IFH

Group from aluminized steel and is used

in an aerial work platform bucket truck.

Hydraulic fluid reservoirs are much smaller

than lubrication reservoirs, which can be

sized for thousands of gallons.

Suction Pressure Available is greater than the Net Positive Suction Pressure Required by the pump, regardless if the pump is a dynamic or positive displacement pump. This ensures that the fluid flowing through the pump suction line is at the recommended feet per second. By maintaining a laminar fluid flow, energy loss through heat in the piping is lowered and the possibility of cavitation in the pump and discharge piping is greatly reduced.

Improper fluid levels in the reservoir will not only affect the overall efficiency of system operation; the increased or decreased velocities can cause system component damage leading to extended down time and expensive repairs. FPW

FPW_Training 8-15_Vs3 MG.MD.indd 33 7/29/15 1:58 PM


Edited by: Michelle DiFrangia • Assistant EditorSAFETY

Proper component selection is critical to design a safe hydraulic system. Although couplings are a small component, they play a major role in hose assembly safety. A hose end coupling connects the hose with a port, adapter, another coupling, or attachment such as a quick disconnect. A mismatched coupling could spell disaster; therefore, it is imperative that the coupling selected is compatible and approved for use with a given hose. STAMPED, an acronym for the seven major information areas required to provide a quality hose assembly, is an excellent resource in this matter.

Choosing the proper stem and ferrule depends on the specific hose and terminal end being used in the assembly. When using two-piece couplings, it is important to match the ferrule with its appropriate stem and hose. Ensure operations run smoothly by checking the manufacturer’s recommendations and crimp specifications. Keep in mind that hose from one manufacturer is not usually compatible

with couplings from another. To avoid potential injury and damage, do not intermix hose and fittings from two manufacturers without prior approval from both parties. Hydraulic fluid leaks can significantly decrease the effectiveness of the system, and pressurized fluid can cause major injection injuries to users.

Follow these parameters when determining coupling selection:• size of hose it will attach to• type of hose it will attach to• terminal end connection—typically

threaded or flanged• coupling type (permanent/field or

attachable/clamped)• coupling configuration (straight, angled,

drop dimensions)• system operating pressure

Properly identifying thread measurement is also key to maintaining a safe system. The proliferation of threads in today’s market makes it easy to mismatch them, resulting in leakage and possibly serious accidents. Correct thread identification begins with the right tools and reference materials, such as a coupling suppliers catalog. The recommended tools are as follows:• thread pitch gauge • I.D./O.D. caliper • seat angle gauge• reference materials showing different

threaded end charts

There are three basic steps to identify the correct coupling/end connection: measure the thread pitch, measure the thread diameter and determine the seating angle, if applicable.

Compatible couplings ensuresafe systems

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SAFETY


Discuss This

Start by using the thread pitch gauge to determine the number of threads per inch (distance between two threads), trying different thread gauges for the tightest fit. Engage as many threads as possible—the more threads engaged, the more accurate the reading. Hold the fitting and thread gauge up to the light and look for gaps or light appearing between the gauge and threads. Best safety practices call for a tight fit with minimal light coming through. However, take care not to over tighten, as this can distort the threads too much and create a path for leakage around the threads.

The I.D./O.D. caliper is used to measure thread diameter. Male thread diameter is measured on the outside diameter, while female thread diameter is measured on the inside. When measuring male thread, hold

the caliper at a slight angle for the most accurate reading; hold it perpendicular to the thread for female. If the connection seals on a flared surface or on an inverted angle seat, the next step is to determine that angle of seal. Place the seat angle gauge on the sealing surface (insert the gauge into the connection first if female). If the centerlines of the connection and gauge are parallel, the correct angle has been determined.

It is also important to keep in mind that the hose assembly (coupling and hose) is only one component of the system. In choosing the correct end terminations for the couplings attached to the hose, formal design standards and sound engineering judgement should be used. If you have questions about what end fittings to use, defer to your product safety guide or NAHAD Hose Safety Institute Distributor.

Special thanks to the NAHAD Hose Safety Institute for providing the material for this article. Information was taken from the Handbook for the Design and Specification of Safe Hose Assemblies. FPW

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HydraForce 8-15.indd 37 7/29/15 12:51 PM

Eric Bucci • Oil & Gas Segment Manager • Trelleborg Sealing Solutions


Successful offshore sealing

FPW_Hydraulic Sealing_8-15_Vs8 MG.MD.indd 38 7/29/15 2:15 PM


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

Eric Bucci • Oil & Gas Segment Manager • Trelleborg Sealing Solutions

Hydraulic systems in marine environments require a complex combination of specialized seals. Understanding the different materials and styles is critical to a safe, successful design.

Hydraulic applications are challenging to seal. Not only must the hydraulic seals prevent leakage of fluid from the cylinder, but they must also withstand high pressures, extreme temperatures and transverse forces within the cylinder. The function of hydraulic seals goes far beyond preventing fluid leakage. Hydraulic systems are not sealed with one seal, rather a complex combination of specialized seals. Hydraulic rod seals prevent leakage of fluid from within the cylinder to the outside, while hydraulic piston seals prevent fluid from flowing across the cylinder head. This allows pressure build-up on one side of the piston, making the cylinder extend or retract. Wear rings guide the piston and piston rod within the hydraulic cylinder, absorbing transverse forces and preventing metal-to-metal contact. Scrapers—also called wipers—scrape dirt, foreign particles, chips or mois-ture from the piston rods as they retract into the cylinder, preventing contamination.

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Special considerations for offshore sealingThe same principles apply to hydraulic sealing, what-ever the application, but offshore sealing systems must stand up to extreme pressures, destructive pro-cess chemicals and marine environments. In addition, sealing materials need to meet industry standards such as API and NORSOK, while being able to respond to an ever-changing technological horizon. As wells become deeper and processing more aggressive, the working conditions for seals and bearings become more demanding. Avoidance of downtime is a key aspect as the costs associated with this can be huge in the oil industry. Close collaboration between operators, equip-ment and sealing suppliers is vital in ensuring long seal life and minimized downtime. One of the most important factors in successful seal specification is understanding the conditions in which equip-ment will operate. This way, the sealing system can be matched to specific requirements in terms of pressure, temperature and most significantly, media compatibility. Process chemicals can destroy seal materials if not correctly specified. In terms of materials, there are many options—from basic acrylonitrile butadiene polymer (NBR) to perfluoroelastomer (FFKM) compounds such as Iso-last, a material that has the elasticity of an elastomer and compatibility of a PTFE, or to polytetrafluoroeth-ylene-based seals, which are inherently compatible with virtually all media as well as polyethylenes.

Not only are the materials of seals important, but also their geometries, as each seal within a hydraulic sealing con-figuration has a specific job to do. The geometries, which have evolved and been enhanced over many years based on ap-plication experience, allow the seals to provide a specific func-tion within the sealing system to meet the varying demands of differing applications. For instance, downhole tools need solutions that withstand extreme temperatures and aggressive media. They require a sealing system to give extended life to allow oil and gas extraction from the lowest depths. Reliability and leak-free operation are critical. For tensioner cylinders, a 20-year or longer maintenance-free seal life is designed to prevent downtime and loss of revenue. In hydraulic swivels, in-creasing speeds and pressures call for innovative seal designs that give low-friction operation.

Select proven solutionsA wide range of proven sealing options is available to the oil and gas industry. Elastomer materials must be carefully se-lected to meet temperature requirements and be compatible with system media. For the offshore industry, elastomers are usually used with other materials such as PTFE-based com-pounds; the elastomer provides the elasticity and the PTFE provides low-friction properties. In high-pressure dynamic sealing applications, elastomers can be supported with PEEK (polyetheretherketone) anti-extrusion rings. The V-stack, for instance, is a multi-component rod seal using multiple chevrons or “Vees” to produce a high integrity seal with multiple redundancy points. These are typically used in rod or piston sealing on downhole tools, particularly


Downhole tools require solutions that

withstand extreme temperatures and aggressive

media. Offering extended life, they allow oil and

gas extraction from the lowest depths where

reliability and lock-free operations are critical.

This tool incorporates both the V-stack and Glyd

Ring from Trelleborg Sealing Solutions.


Mico 8-15_FPW.indd 41 7/29/15 12:52 PM

on hydraulic setting tools for packers or plugs where conditions are challenging. V-stacks can cope with high temperature and pressure, especially when combined with unknown hardware conditions or “blind stab” applications. The seal can have several Vees in differing materials, usually mated with PEEK anti-extrusion and adapter rings. This results in a proven and robust sealing option. The Glyd Ring is good for a double-acting seal, primarily on hydraulic pistons, but also as a rod seal. In its compact design, an elastomer component provides a pre-tensioning element to maintain low-pres-sure sealing integrity, while a PTFE-based or polyethylene sealing component gives the seal low-friction performance. The seal design is well suited to coping with large

applications. An excellent one-fit solution for generic equipment, they can be used in many different regions, in various operating conditions and with a variety of media. The seal provides good low-friction properties and can either be used on its own or paired with a PEEK anti-extrusion ring and support ring, or even Vee rings for high pressures. The spring of the spring-energized seal is housed in a PTFE-based jacket, and being a completely non-elastomeric sealing solution, it withstands oil and gas related media while operating in a broad range of temperatures from -200 to 230° C. Spe-cial designs, such as Trelleborg’s Turcon Variseal M2S, can also function as a scraper in subsea hydraulic cylinders, such as valve actuators on subsea trees. To specify the optimum seals for a hydraulic application, you should talk to a seal specialist. There are, however, tools to assist in initial selection. For example, an online compatibility check is available on Trelleborg’s website; engineers can input the media that sealing systems will be exposed to and it provides the best recom-mendations of compound types to use. In addition, a Sealing Solutions Configurator gives recommendations for high and low pressure hydraulic swivels. Sealing configu-rators like these simplify seal selection and help ensure safe, long-lasting systems. FPW

Trelleborg Sealing Solutions tss.trelleborg.com


Discuss This



tolerances or axial loads exerted on the cylinder. Enhanced over several generations and in multiple industries, the hydraulic Turcon Stepseal II is used for rod or piston sealing and is usually fitted in pairs to produce a “back pumping” effect, reducing leakage and maximizing sealing performance. A fur-ther development specifically engineered for the oil and gas industry is the Turcon Stepseal Anti-tilt; an excellent choice for use in tensioner systems. This seal is also available in wear-resistant Zurcon polyeth-ylene compounds for use in low-lubricity, water glycol hydraulic fluids. Metal springs can offer an alterna-tive to elastomers for providing elasticity. Spring-energized seals are one of the most proven sealing solutions in oil and gas

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

Hydraulic press

Josh Cosford • Contributing Editor

safetyis vital in automotive manufacturing


Automotive manufacturing plants

like this Nissan operation in

Bangkok, Thailand, have many

moving parts—meaning that safety

must always be a concern.

FPW_Industrial feature_8-15_Vs6 MG.MD.indd 44 7/29/15 2:25 PM


The most highly regulated sub-market

within the automotive manufacturing industry is

the hydraulic press segment. The hydraulic press is

located in every corner of automotive manufactur-

ing, from injection molding of plastic bumpers to the

hydroforming of chassis components. Some presses

can be tiny, such as those used to stamp out small

metal components for a dashboard support bracket.

Other presses are absolutely enormous, like those

used to stamp sections of frame rail; in fact, large

enough to fit an entire person into the die.

The potential for personal harm at the hands of a punch press, injection-molding press, press brake or forge press is extreme. Presses can range from 5 to 100,000 ton or more, and even the 5-ton press can shear skin and bone like butter. Also, a punch press, for example, can operate at blinding speeds, leaving no time for operators to move their hand or body out of the way should a cycle be accidentally started. Because of the dangerous nature of the hydraulic press, various governmental or bureaucratic bodies have spelled out the particulars of press safety to ensure press-related injuries are avoided in automo-tive and other manufacturing environments.

Safe environments rely on a complex

system of components, from

redundant control valves to rod locks,

and light curtains to linear position

transducers.


to signal the machine to shut down should a hand reach inside a stamping press, but it’s more difficult to ensure the machine is safe even after the e-stop is triggered. To be safe, not only must the press stop the load or platen from dropping, but the press must be prevented from restarting accidentally while the machine is in safe mode. Because of the current lean nature of automotive manufacturing, parts and components need to be supplied as closely as possible to the time they’re welded, bonded or bolted to the vehicle they’re home to. Lean manufacturing requires frequent changeover of tool and die in the manufacture of vehicle components. For an injection molding machine making dashboards, for example, the horizontal movement of the press is quite safe during mold changeover, as it is simply lifted out and replaced with an overhead crane. For other hydraulic press examples, such as with a tandem line used for manu-facturing floor pans, the vertical platens can weigh thousands of pounds. When they are changed for a different line, it must be done with platens in the air after the dies are removed. Even in the machine-off mode, several precautions must be taken to

INDUSTRIAL HYDRAULICS

In the U.S., machine build standards must adhere to OSHA 1910 regulations for Machinery and Machine Guarding. The OSHA regulations apply to general machine safety requirements, and also to non-press machinery. The regulation covers anti-tiedown (two handed operation), machine guarding, electronic safety devices (such as light curtains and limit switches) and other safeguards. These measures are especially important to a hydraulic press, but little of it is specific to a hydraulic press alone. In Europe and Canada, the codes for hydraulic press safety are much more rigid, requiring even a used press to go through an extensive upgrade before it is commis-sioned into operation. The European Union uses the EN 693 standard, and in Canada the CSA Z142 code applies to any new or upgraded machine. Both standards are in addition to general machine guidelines and are specific to the hydraulic operation of the press. Both codes ensure that human interac-tion in locations where there is potential harm is kept to a minimum, and also that the machine is entirely safe in tool change or emergency stop situations. It’s common practice to use a light curtain, for example,


ensure the platen stays aloft, preventing it from falling and crushing workers. Employing redundant, monitored control valves is the most common tactic to ensure the machine cannot press ac-cidentally. Two inline valves, either after the pump or to control the cylinder(s) will provide redundant control, so that if one valve is stuck open, the other can close to prevent the press from further energiz-ing. By monitoring these two valves with an electronic switch, the PLC can also determine the valve position is safe prior to machine startup, preventing undesired, accidental movement should one of them be stuck. When two valves are used inline at the cylinder work port, they can also bleed the work port directly to tank to ensure there is no trapped pressure, which could potential-ly move the platen or load. If the redundant valves were used at the pump, a separate, single monitored valve can be used to dump work port pressure to tank while in the safe mode. Using redundant valving with dump-ing capability is often referred to as “block and bleed.” Additional safety functions can be added to the hydraulic press, above and

Banner Engineering’s safety type 4 light curtains are non-contact machine guarding systems. They are ideal for protecting hands, fingers and ankles and guarding perim-eters and access.


Veljan Hydrair 8-15_FPW.indd 47 7/29/15 12:53 PM

INDUSTRIAL HYDRAULICS


beyond the standard monitored block and bleed. These include rod locks, which can physically hold the rod of the cylinder dur-ing safe modes, such as when dies are be-ing changed. A device literally clamps and holds onto the cylinder rods, so that even if there is a catastrophic oil leak or other damaged component, the platen cannot drop. Limitswitchesorlinearpositiontransducerscanreadcylinderpositionatalltimeswhenthemachinehaspower,which lets operators know the press is in safe mode. Just as with the redundant, monitoredvalves,positionsensorscanalsopreventthemachinefrombeingfiredupwhen dies are being changed. However, mostautomotivemanufacturersandTier1suppliers have strict company-wide safety procedures when working on machines,

and most require individual technicians to lock-out the press’ electrical panel anyway, which obviously prevents any power from reaching the machine. From a hydraulic standpoint, some presses are so extremely safeguarded as to use a relief valve on the rod port of the cylindertopreventintensificationfromdamaging the cylinder seals. A leaking cylinder seal could allow the load to drop unintentionally,whichisclearlyunsafeinanycondition,notjustduringdiechange.Theexactmeasuresusedinautomotivehydraulic press safety are dependent on thegeographyofinstallationandtheengi-neerscertifyingthemachine.Anymachineupgradesshouldbedoneonlybyqualifiedpersons,withconsiderationforelectronic,mechanicalandhydraulicintegrationofthechosensafetytactics.

Theautomotivemanufacturingindustry is the largest, most advanced andtechnologicallysophisticatedintheworld, and with state-of-the-art manufac-turing techniques such as hydroforming andcarbon-compositeinjectionmoldedbody-panels,productivityandefficiencyare not slowing down. Size, performance and speed are always improving, and with it comes the need for increased safety considerations. FPW


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Visit us at: www.PrinceHYD.com

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P N E U M A T I C S

The biggest change pneumatic cylinders have seen in the past couple of years has

been environment-driven. Engineers are requiring better performance from their cylinders

and they’re requiring it in much more demanding applications. These environments in-

clude, but are not limited to, medical, hydroforming, foundries, and food processing and

packaging. These demanding environments are pushing the limits of the materials and

speeds of cylinders, and we are seeing new seal compounds being used to overcome

those problem areas.

“Once you add the speed and force requirements on top of the environment concerns, the challenge becomes putting together the correct combination. De-manding applications require high-speed, low-friction seals and long life. One or two of these would be easy; however, all three make it a constant challenge,” said John Ross, AVP of Segment Management, PHD Inc.

The newest pneumatic cylinders have a wide range of specifications and features to address specific issues. Here is what you need to know.

ISO configurationsThe Numatics 449 Series compact tube cylinder, 450 Series heavy-duty tie rod cylinder, and the 453 Series hygienic tube cylinder are all available in a vari-ety of ISO configurations. The 449 Series Cylinder is an ISO 21287, single-acting, single-rod, non-rotating cylinder with a short profile tube design and a wide choice of standard mountings and rod ends. The 450 Series is an ISO 15552, square tie rod designed for low friction and easy maintenance.

Extreme environments have forced pneumatic cylinders to adapt. Here’s a look at some that meet these challenges.

New environments challenge pneumatic cylinders


Edited by: Mike Santora Associate Editor

FPW_Pneumatics 8-15_Vs9 MG.MD.indd 50 7/29/15 4:22 PM


Fabco-Air’s new OEM NFPA cylinders have stainless-steel tie-rods incorporated into the cylinder construction, as well as anodized end caps.

The Numatics 449 Series has a Reed-switch type or magneto-resistive type (MR) installation into the T-slot grooves. The cylinder also has a self-lubricating bearing and a non-abrasive scraper seal.

Photo courtesy of FESTO


P N E U M A T I C S

It has a self-lubricating bearing, non-abrasive wiper seal, a permanent magnet and either a REED switch or Hall effect sensor for position sensing. The 453 Series has a profile tube de-sign suitable for packaging and clean aesthetic requirements with a full range of options. With one “clean” side with no retention areas, this improved design has no tie rods, resulting in a lighter cylinder.

NFPA interchangeable cylindersFabco-Air’s OEM NFPA Cylinder line is a repair-able NFPA interchangeable cylinder line that is specifically designed to give users an eco-nomical cylinder option. The cylinders come with magnetic pistons for position sensing. Adjustable cushions are included at both ends of the cylinders as well. Stainless-steel tie-rods are incorporated into the cylinder construc-tion, as well as anodized end caps. Each cylinder includes both bottom tapped and end-cap sleeve nut mounting configurations. NFPA mounting is made easy by simply adding one of the detachable NFPA mounts that is offered with the standard cylin-der. Aventics’ NFPA cylinders include Pow-erMaster pneumatic cylinders, rated for pressure to 250 psi. Bore sizes are 11⁄2 to 14 in., with some limitations on the 14-in. Pres-sureMaster. Over 20 NFPA standard precision machined mounting styles are available, with many options for piston rods, rod threads, ports, seals, stop tubes and limit switches. Aventics NFPA cylinders can interchange with


The DRRD from Festo offers high load capacity at torques from 0.2 to 112 Nm and a maximum mass moment of inertia of up to 420,000 kg/cm2.Photo courtesy of FESTOHose, tube and pipe cleaning and sealing solutions.

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5 4 FLUID POWER WORLD 8 • 2015

P N E U M A T I C S

other manufacturers’ NFPA cylinders. An online configurator is available for configuring a custom cylinder and provides a part number and CAD files.

Field-repairable optionsTo provide an alternative to its “built-to-order” product line, PHD Inc. released a new metric design of its Optimax Series OCG round-body pneumatic cylinder. These actuators are designed to be more versatile and economical for use in the machine builders’ market. The actuator’s features include: imperial and new metric designs, field repairability, six bore sizes with 10 stroke lengths, drop-in mount-ing to match global standards, standard cushions to reduce end-of-travel impact and magnets that come standard for switch sensing capability.

Twin-piston semi-rotary drivesThe DRRD from Festo offers high load capacity at torques from 0.2 to 112 Nm and a maximum mass moment of inertia of up to 420,000 kg/cm2. This enables smaller sizes to be used without sacrific-ing power, which reduces cost and saves space in handling and assembly technology or in machine building. The optimized housing and piston drive design of the DRRD can also handle harsh industrial conditions. Size 16 and above of the DRRD can be equipped with an end-position lock for mechanical locking in the end or mid position. Other options include: fully sealed variant for wet or dusty envi-ronments, external position sensing version with sensor mounting, immediate position model and one external and two internal cushioning types. An energy through-feed model also provides fast and easy supply of electrical signals or compressed air transferred through a hollow shaft.

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Your Partnerin Automation Solutions

Are downtime and inventory costs interfering with your productivity? PHD’s automation solutions can help.

- Performance pneumatic and electric actuators designed for long operating life

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PHD welcomes the challenges of many different types of operating environments. Fast delivery reduces inventory costs, keeping your production schedule on track. PHD is your partner in helping you find the right solution for your automation needs.

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PHD’s Optimax Series OCG features imperial and new metric designs, field repairability, six bore sizes with 10 stroke lengths and drop-in mounting.


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The semi-rotary drive DRRD operates on a rack and pinion principle with high accuracy in the end positions. It has high bearing load capacity and the splash proof design meets IP65 and EN 60529 standards.

Stainless-steel pneumatic air cylindersAutomationDirect’s NITRA product line includes F-Series air cylinders for washdown. The non-repairable, round-body cylinders are inter-changeable with other brands. The double-act-ing cylinders have a 250-psi operating pressure and are constructed with corrosion resistant 300 Series stainless steel and Teflon-based rod and pivot bushings. The Urethane rod wiper keeps washdown solutions out of the cylinder. The series includes bore sizes from ¾ to 2 in. and stroke lengths from ½ to 18 in. Models feature nose, rear pivot and double-end mount-ing options and an optional magnetic piston for position indication. The company has also added accessories to help with control. According to Pat Phillips, product manager of Fluid Power and Mechanical Products at AutomationDirect.com, “The use of miniature inline pressure regulators, with built-in relief, provides easily installed cylinder force control. The flow control, pressure indicator and inline hand valves are an inexpensive option for speed control, air status, quick exhaust and isolation of an air cylinder. These devices can control, tune, indicate and isolate pneumatic cylinders.” FPW

5 6 FLUID POWER WORLD 8 • 2015

P N E U M A T I C S

Aventics’ PowerMaster pneumatic NFPA cylinders (pressure to 250 psi) can inter-change with other manufacturers’ NFPA cylinders. An online configurator is also available for configuring a custom cylinder and provides a part number and CAD files.

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Discuss This


fluidpowerconnections.com • (732) 792-0411

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COMPONENT FOCUS


Edited by: Paul J. Heney • Editorial Director

Fluid conditioning is the top priority for those intending to keep their mobile hydraulic machinery happy and reliable. Control of the various forms of fluid contamination ensures that components will run within their design criteria efficiently and dependably. Major forms of fluid contamination include water, air, heat and

particle. Particle contamination is often highest during machine startup. This is where the remains of cutting, grinding and welding have found homes in the nooks and crannies of reservoirs, manifolds, hoses and actuators. Contamination can spike once again during careless maintenance or catastrophic component failure. Luckily, particle contamination is extremely easy to control, which makes it all the more shocking when people don’t take filtration seriously.

Every hydraulic machine requires fluid filtration, and there are three major types—suction filters, pressure filters and return filters. Suction filters are mounted inside the hydraulic reservoir on the suction tube as a primary defense against larger chunks, but are made of steel mesh and limited in their capacity to reduce the finer wear-causing particles. The use of suction filters is also a bone of contention, as some feel they cause more problems than they solve, such as becoming clogged and creating pump cavitation.

Pressure filters are installed downstream of pumps or in sub-circuits of the system requiring different, and often finer, levels of filtration than the rest of the circuit. Installed after the pump, a pressure filter can protect all the components downstream from anything ingested by the pump. Depending

on how they are rated from their manufacturer, pressure filters can range from 500 to 10,000

psi and higher, adding insurance in even the most demanding hydraulic application.

Return filters are the most common form of fluid protection in mobile hydraulic systems, and are normally either spin-on filter assemblies or in-tank drop-in assemblies. The venerable spin-on filter resides on the vast majority of mobile machinery, and is available in low- to mid-range quality filter media. They are sometimes outfitted with water absorbing filter media, which can remove freestanding water from oil, if such a problem is a concern.

In-tank return filters, previously the realm of industrial hydraulics only, have infiltrated the mobile market as well. They offer medium- to high-quality filter media in a convenient and space-saving mounting configuration. Their location in the fluid stream, as with spin-on return filters, allows them to remove many of the particles created or ingested by the rest of the system, leaving a reservoir full of sparkly-clean oil.

Filters are classified by the smallest size of particles that they reasonably remove from the oil in one pass through the element, such as “10 micron.” It is important when discussing filtration quality that the efficiency is stated for which the rating was classified. For example, a 10-µm filter requires that we know how efficient it was at removing 10-µm particles in a single pass, such as 99%. Efficiency is often expressed as a beta ratio, which is the ratio of particles upstream of the filter to downstream of the filter during standardized testing; for example, “10 µm at Beta 200,” which means 99.5% efficient at removing 10-µm particles in one pass. Obviously, lower micron filtration and higher efficiency is ideal, although price can be a consideration as filtration quality rises. Finer filtration is more restrictive, so attention to pressure drop detail should be paid, just as sizing any filter to be appropriate for the flow of the circuit should be considered. FPW

Filtration in mobile machinery

FPW 8-15 Component Focus_Vs4 MG.indd 58 7/29/15 2:08 PM


PRODUCT WORLD

Cylinder-position sensorsBalluff Balluff.com

A high-pressure, inductive proximity

sensor, the Strokemaster provides a

2-mm (0.08-in.) sensing range to detect

the “spud” of hydraulic or pneumatic

cylinders, which indicates fully retracted

or extended position. It mounts with

just two screws and seals with an O-ring.

Withstanding cylinder pressures to 3,000

psi (207 bar), the embeddable design

keeps most of the switch protected within

the cylinder, with only a 16-mm (0.62-in.)

high housing exposed outside. The sensor

housing allows 304° of rotation that eliminates the hassle of post installation

cable adjustments. This rotating feature also eliminates the need to unbolt the

flange from the cylinder and breaking the seal.

Coalescing filtersBimba ManufacturingBimba.com

Coalescing filters protect sensitive

pneumatic equipment from the harmful

effects of air-line contamination by

removing fine oil mist and contamination

down to 0.01 μ. Fine borosilicate microfibers in

the filter media collect microscopic particles,

while the outer filter drainage layer allows

coalesced liquid to fall into the filter bowl.

Multiple drain styles, including manual,

automatic and semi-automatic, are available.

Particle counterARGO-HYTOS Argo-hytos.com

The OPCount is a particle counter

that can be used for stationary and

mobile operation. High measuring

accuracy is combined with the

ability to display the measured

particle concentration according to all

current standards. Measurement can be carried

out directly at a pressure line or from a bottle,

using the integrated pump or at system pressure

up to 420 bar.

Hydraulic shock absorber

Deschner Deschner.com

The new Impacta line of hydraulic shock absorbers are

self-adjusting, feature the M25 threaded body and offer

a longer cycle life. Maintenance free and leak resistant,

due to a unique sliding seal system, the absorbers are

equipped with a flexible rod wiper to prevent dirt, chips

and moisture from entering the unit. Available initially

in a stroke length of 1 in. with a capacity of up to 900 lb,

they are suitable for use on high-speed machines, such

as reciprocating slides, flying die cut-off machines, roll

forming equipment and packaging machines.

FPW_Product World_8-15_Vs3.MD.indd 59 7/29/15 2:48 PM


AD INDEX

Aggressive Hydraulics .....................18Alro Steel Corp. ...............................56Anchor Fluid Power .........................23Anderson Metals Corporation, Inc. ......................25AutomationDirect .............................1Bimba ................................................9Brennan Industries ..........................11Camozzi Pneumatics Inc. ...........19,42 Clippard Instrument Laboratory .....BC FABCO-AIR, Inc. ...............................53 Festo ..................................................2Firestone Industrial Products ..........15 Flaretite, Inc. ...................................19 Fluid Power Connections .................57Gerdau Special Steel North America .........................31Hengli ..............................................21Holmbury, Inc. ...............................IBCHunger Hydraulics ...........................30 HydraForce ......................................37

Hydraulex Global .............................49 IC-Fluid Power, Inc. ..........................27 igus, Inc. ..........................................43Kocsis Technologies, Inc. .................55Kurt Hydraulics ................................13Lillbacka USA, Inc. ...........................29Main Manufacturing .........................4 MFP Seals ........................................17 MICO, Inc. ........................................41 Muncie Power Products ....................5 OP Srl ...............................................35PHD Inc. ...........................................54 Prince Manufacturing Corp. ...........48 Servo Kinetics ..................................36 Smalley Steel Ring Company .............3Super Swivels ..................................10Tompkins Industries .................... IFC,4Ultra Clean ......................................52Veljan Hydrair LTD ...........................47 Webtec ............................................14Yates Industries .................................7

www.fluidpowerworld.com

LEADERSHIP TEAM

PublisherMike Emich508.446.1823 [email protected]@wtwh_memic

Managing Director Scott [email protected]@SMMcCafferty

EVP Marshall [email protected]@mmatheson

Ad Index_FPW_8-15.indd 60 7/30/15 2:48 PM

VISIT US ATICUEE 2015

BOOTH 2217

TEL: (866) 465 6827FAX: (440) 578 1073EMAIL: [email protected]

HOLMBURY INC.33801 Curtis Blvd, Suite 104

Eastlake, OH 44095

Connect with quality - Connect with Holmbury

Holmbury has recently expanded their hydraulic quick coupling offering to include the HDB Series. The HDB Series is a connect under pressure block coupler designed specifically for the skid steer loader market and is interchangeable with the Faster

4BD4FH and Stucchi Saturn block couplers.

HDB Advertisement- Full Page v4.indd 1 29/07/2015 14:46:00

Holmbury 8-15_FPW.indd 1 7/30/15 2:20 PM

PneumaticCylinderSwap

Clippard Instrument Laboratory, Inc.877-245-6247 • www.clippard.com

For over 50 years, Clippard has been providing quality cylinders for thousands of applications around the world. Cylinders that are responsible for millions of production cycles. Cylinders that provide outstanding performance and payback. Cylinders that quickly became the preferred brand!

Swap your existing pneumatic cylinder with the Preferred Clippard brand.

• Providing a level of credibility above the competition

• Durable, economical construction

• Exceptionally long cycle life

• Interchangeable design

• Many stroke and bore sizes

• Proudly made in the USA

Many Styles, Materials, Bore Sizes & Strokes

Available.

The Great Vegas Cylinder Swap of 2015!

PACKEXPO Booth C-2425

Visit PACKEXPO booth C-2425 to have your existing pneumatic cylinder swapped for the trusted Clippard brand. (Please present the existing competitive product, item number, photo, prototype or current application. Offer valid on standard models, bore sizes and materials September 28 through 30, 2015.)

Clippard 8-15_FPW.indd 1 7/29/15 12:56 PM

Documents

Fluid Power World August 2015