1. Eliminating Weak Links: How a Pressure Sensor Can Affect Equipment Reliability WIKA Electronic Pressure Measurement for Mobile HydraulicsMiningAgricultureConstructionWhy WIKA?ProductsContact Us1

2. Choose Equipment ReliabilityYou know the old clich: a chain is only as strong as its weakest link. Likewise, your equipment is only as good as each of its components.Every year, your customers must overcome a number of obstacles that threaten their operations: increasing material costs, unpredictable weather, government regulation, and unplanned equipment can help them by ensuring the reliability of your equipment. So, you painstakingly design and oversee the implementation of your equipment until all of your from an angry customer with a machine down... because a small part failed. This eBook will cover the downside of selecting the wrong sensor as well as the criteria forMiningAgricultureConstructionWhy WIKA?ProductsContact Us1 3. equipment. They monitor a variety of functions, such as controlling operating pressure, load pressure, brakeSteering system Combustion engine ECU Electronic control unitCooling systemMain hydraulicsSuspension systemHydraulic traction driveCRITICAL TO FUNCTION (CTF) Measure pressure to control critical systemsMiningBrake safetyCRITICAL TO SAFETY (CTS) Measure pressure to provide warning of unsafe conditionsAgricultureConstructionWhy WIKA?BASIC MONITORING Measure pressure to ensure consistent performanceProductsContact Us2 4. The Cost of Failure: Worth the Risk?customer.INITIAL COST OF SENSORSCOST OF FAILUREPurchase Price, Maintenance, Supply Chain CostsDowntime Costs, EnvironmentalTake the failure rate of cheaper transmitters, and then multiply this failure rate by the number of units per year.You can lose thousands of dollars in lost productivity per day if your equipment fails.MiningAgricultureConstructionTOTAL COST OF OWNERSHIP (TCO)Why WIKA?Saving a few dollars per unit on a cheap pressure sensor can lead to a higher TCO.ProductsContact Us3 5. Hear how the wrong part can lead to downtime.MiningAgricultureConstructionWhy WIKA?ProductsContact Us4 6. Downtime is More Than a Machine... Its Your Entire Production Line1One of your excavators breaks down...2 34 trucks and their drivers stop working...5A dozer and its operator stops working...4MiningAgricultureYour customer demands an explanation.You lose tens of thousands of dollars per hour...ConstructionWhy WIKA?ProductsContact Us5 7. Selecting a Sensor: Mining Some of the key criteria for selecting a pressure sensor include: Shock and Vibration Shock and vibration can eat away at a pressure transmitter. Having a sensor that cannot withstand these forces could lead to unnecessary downtime. Electrical Interference EMI/RFI interference on a mining site, or on any site, can cause signal instability and inaccuracy in the pressure transmitter. Temperature Equipment using mobile hydraulic systems areThese temperature changes affect pressure transmitters as they do any electronics. Water Ingress that can weather the high pressures and temperatures that are present during a high pressure wash down. Not to mention being able to stop water from entering the unit in all kinds of wet environments.MiningAgricultureConstructionselecting a sensor that can withstand the harsh conditions mining equipment must face.Why WIKA?ProductsContact Us6 8. Nutrient inputs are responsible for between30-50% of crop yield.*True Cost of Failure: Agriculture* Source: http://www.ipni.net/ppiweb/ppinews.nsf/0/7DE814BEC3A5A6EF85256BD80067B43C/$FILE/Crop%20Yield.pdfMiningAgricultureConstructionWhy WIKA?ProductsContact Us7 9. The Cost of Breakdown Nutrient inputs are responsible for between 30-50% of crop yield1...Down machine cost = $7,000/hr. in rental cost alone.2 working properly, then you can end up applying too much or too little material in a certain area...Resulting in the possibility ofdecreasing your crop yield.1 Source: http://www.ipni.net/ppiweb/ppinews.nsf/0/7DE814BEC3A5A6EF85256BD80067B43C/$FILE/Crop%20Yield.pdf 2 Source: Industry studiesMiningAgricultureConstructionWhy WIKA?ProductsContact Us8 10. Selecting a Sensor: Agriculture Some of the key criteria for selecting a pressure sensor include: Shock & Vibration Something as simple as a running engine can actually shake apart the sensor over time. YouChemical Compatibility You want to make sure the sensor is compatible with the material your customer will be applying. Chemicals and fertilizers can degrade the sensor over time. Survive the Environment You need a pressure sensor that can survive the environment in which your equipment is used. Hear how to select a pressure sensor for the agriculture industry.into the sensor. This may disrupt the electronics and skew the output.MiningAgricultureConstructionWhy WIKA?ProductsContact Us9 11. True Cost of Failure: Construction Pressure transmitters help indicate that the application is within safe operating parameters. Combined with boom height and boom length, pressure is integral to whether or not construction equipment is safely being operated.MiningAgricultureConstructionWhy WIKA?ProductsContact Us10 12. can cost your company+$1,000,0001$152,000Down Machine$225/hr. $7,0001Without Lost Work Day$28,0001With Lost Work Day$910,0001Indirect Costs 2equipment rental cost alone1In addition to personal injury costs, an accident affects production. These indirect costs can include schedule delays, repairs to damaged property, maintaining insurance coverage, and added administrative time, not to mention losing the trust of your most valuable customers.With Death1 OSHA average costs, includes both direct and indirect costs, excludes property damage. 2 WIKA industry researchMiningAgricultureConstructionWhy WIKA?ProductsContact Us11 13. of a failed pressure sensor.MiningAgricultureConstructionWhy WIKA?ProductsContact Us12 14. Selecting a Sensor: Construction Some of the key criteria for selecting a pressure sensor include: Long-Term Stability The performance of a transmitter on day one is obviously essential, but its performance in year two, three and beyond is even more important. Shock and Vibration Is this a pressure transmitter that is going to be able to withstand the shocks and vibrations that are commonly present in a construction site? What about internal stresses such as changing loads and cavitation? Pressure Spikes You can have huge pressure spikes when youforce sends waves of pressure back to the sensor. Hear how to select a pressure sensor for the construction industry.MiningAgricultureConstructionWhy WIKA?ProductsContact Us13 15. So you never have to apologize to a customer with a machine down.MiningAgricultureConstructionWhy WIKA?ProductsContact Us14 16. Every Product is a PromiseInnovative Product DesignHigh DegreeQuality MaterialsProcess ControlRigorous TestingReal-World Results By manufacturing our products, we can ensure youwith the manufacturer,We can also work with you and your team to help yourquality productcustomizable productproduct innovationsMiningAgricultureConstructionWhy WIKA?ProductsContact Us15 17. We Do Things Differently We believe that all relevant processes and technologies must be under our control. For instance, we make our own sensors to ensure we deliver reliable products.Sensors are at the heart of your monitoring device.While others may outsource this function to avoid relinquish control of something so important.By manufacturing our own sensors, we help decrease defect rates and improve durability and quality.MiningAgricultureConstructionWhy WIKA?ProductsContact Us16 18. Case Study:ChallengeControlling Manufacturing Leads to Supply Chain Solutionshad a lag time of weeks to get parts from their manufacturer. Solution service immediately developed a crossover on an OEM product and made BOM changes on our end. Our manufacturing team produced 1,000 emergency units in one week and shipped them overnight.Results Our efforts allowed the customer to satisfy its customers who were waiting for equipment. Now that we have their stocking agreement to ensure that we have a buffer to avoid any potential delays in the future.*Source: Actual WIKA customer and case studyMiningAgricultureConstructionWhy WIKA?ProductsContact Us17 19. products can withstand the rigors of mobile hydraulics.MiningAgricultureConstructionWhy WIKA?ProductsContact Us18 20. WIKA Real-World Testing performance in all real-life conditions. Putting them through one test after another helpsFunctionality TestsBatch of 10 SensorsFunctionality Tests20 Mechanical Tests50 Environmental Tests10 Electrical Tests Such as OvervoltageHousing Stability and Impact ResistanceSuch as Continuous Shocks, Ice Water, Vibration, Resistance to Chemicals and High Pressureand Radiates FieldThe result is a better product to handle the rigors of mobile hydraulics applications...MiningAgricultureConstructionWhy WIKA?ProductsContact Us19 21. WIKA Products Designed for Your IndustryMiningAgricultureConstructionWhy WIKA?ProductsContact Us20 22. MH-2Mobile Hydraulic Pressure Transmitterwith a metal liner for EMI/ RFI protection.Welded sensor cell provides a leakfree seal that eliminates the need for additional soft-sealing materials.Cavitation Dampening System protects unit from pressure spikes and cavitation.technology provides in applications producing frequent pressure cycles. Can customize to your needs, including special pressure EMI properties in accordance with EN 61326 offer consistent operation even when interference.additional minimum quantity requirements and at very low set-up cost. Cable version provides environmental to high-pressure steam wash-down cleaning procedures.MiningAgricultureConstructionWhy WIKA?ProductsContact Us21 23. MH-2Mobile Hydraulic Pressure TransmitterEMI PCB EMC circuit design for added EMC protectionThis robust sensor features a fully welded design withPlastic case Industry proven plastic to provide long-lasting protection againstprotection by inner metal sleevePressure Connection One piece solid stainless steel pressure against pressure spikes and cavitationstability that keeps calibration for yearsChange-over PCB bond connections to sensor circuitMiningAgricultureConstructionWhy WIKA?ProductsContact Us22 24. Case Study:ChallengeLowering Costs way to reduce the overall costs of their equipment and become more competitive in the global marketplace. This company had been using load cells for decades in order to measure overload conditions. Solution load cells with pressure transmitters. These measurement of the load.Results pressure sensors allowed the company to save money on each and every piece of equipment they manufactured.*Source: Actual WIKA customer and case studyMiningAgricultureConstructionWhy WIKA?ProductsContact Us23 25. MH-1Pressure TransmitterThe MH-1 pressure transmitter has an all stainless steel body for specialized requirements. The all-weldedprovide mechanical protection against system damaged. eliminates need for additional softsealing materials that may deteriorate over time. Sputtered technology provides applications producing frequent pressure cycles. CDS system includes an arc eroded pressure channel for additional protection against pressure spikes and pulsations.MiningProvides ingress protection from IP 65AgricultureConstructionWhy WIKA?ProductsContact Us24 26. MHC-1 Pressure Transmitter instrument concept that has been designed and tested for the severe operating conditions of mobile or J1939 protocol.* CANopen is a Community Trademark of CAN in Automation.or J1939 protocol.Version with integrated Y-connector offers easy and secure installation.High EMC protection shields unit from electrical interference.MiningAgricultureConstructionWhy WIKA?ProductsContact Us25 27. MHS-1 Pressure Transmitterof the safety-critical load monitoring system can be detected by monitoring the dual pressure sensors in the control system, and the actuator can be set to a safe condition if a hazardous condition is detected. This reduces the probability of a dangerous failure and increases process security, not to mention reducing the cost of buying two individual sensors.Channel 1 can be a pressure sensor with Robust stainless steel housing and the proportional electrical output signal and Channel rated electrical connection are designed Hermetically-sealed, welded, its sputtered Wheatstone bridge offers long-term stability in applications with high dynamic load changes. and electrical installation costs are lower than installing two individual pressure sensors.cavitation damping system integral to the process connection minimizes the possibility of pressure sensor failure.pressure spikes.MiningAgricultureConstructionWhy WIKA?ProductsContact Us26 28. WIKA Can Help You Reach Your Goals For a company in a mature, industrial environment, we love a good challenge. We like to say, Give usof engineers to help. Someone in our network has probably already seen a problem that is new to you. we stand behind our products and services.the world for pressure measurement instruments.Contact Us for More Informationemploys more than 7,000 people. When you need WIKA is a registered trademark of WIKA Alexander Wiegand SE & Co. KG., used under license by WIKA Instrument, LP. Copyright 2013 WIKA Instrument, LP. All Rights Reserved.MiningAgricultureConstructionWhy WIKA?ProductsContact Us27