fluid power world may 2016

May 2016www.fluidpowerworld.com

Ag machinery relies on the versatility of hydraulics p.26 Twelve tips for better cylinder selection p.34

PAGE 42

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2 FLUID POWER WORLD 5 • 2016 www.fluidpowerworld.com

Paul J. HeneyEditorial Director

[email protected]

On Twitter @DW_Editor

This week, I had the good fortune to attend the Chainless Challenge, one of the most creative design competitions you’re likely to find. A decade ago, some Parker Hannifin engineers came up with the idea of challenging college engineering students to design a hydraulic bicycle. Basically, students have to strip the chain drive off a typical bicycle and design a hydraulic system that takes the torque generated from pedaling the bike and transmits it to the wheel(s). The Challenge, which started in Parker’s hometown of Cleveland, eventually migrated to Southern California, where it’s held each Spring on the old runways of the decommissioned El Toro Marine Corps Air Station. This year’s Challenge included teams from eight universities: Cal Poly/San Luis Obispo, Cleveland State University, Illinois Institute of Technology, Purdue University, University of Akron, University of Cincinnati, University of Illinois/Urbana, and Western Michigan University. See more about the Challenge in the Association Watch department, on page 10. The Challenge is undergoing a big change, however—the National Fluid Power Association is taking over the reins of the event from Parker next year. Parker has been extremely generous with the Challenge, paying all of the students’ travel costs, not to mention providing components for the actual bicycle builds. The NFPA staff is excited about the future prospects. “I think this program has a lot of potential for growth and my being here to witness it firsthand has really demonstrated—as we talk to the different professors and students—this is a really viable way of getting fluid power instruction into mechanical engineering curriculums,” said Eric Lanke, NFPA’s CEO. “We think that’s where the scalability issue is going to be most focused. We’re going to be investing our resources to not just organize [the Challenge] but to help it grow, to get more and more schools involved in this activity.” I hope Parker stays actively involved, but I’d also love to see other manufacturers step up and offer their support (including donating components) to these kids. Maybe a few fluid power distributors can get involved, too. Who’s up to the Challenge of helping this worthwhile program? I hear a continual stream of comments in our industry that we need to increase the amount of engineers graduating from college who know fluid power. Here’s a real way that we can do just that. Getting these kinds of college students excited about fluid power means there will be that many more potential hires in the coming years. And that’s a challenge we all have to address. FPW

Editorial 5-16 FPW_Vs2 MG.indd 2 5/12/16 11:07 AM

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4 FLUID POWER WORLD 5 • 2016

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Staff Page_Fluid Power World 5-16.Vs3.MD.indd 4 5/17/16 12:19 PM

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12

10


ON THE COVER Custom vacuum-handling systems that rely on modular parts, such as independently zoned layer grippers, speed up design, reduce cost and improve efficiency and performance. Image courtesy of Schmalz Inc.

26

D E PA R T M E N T S

02 Editorial 08 Korane’s Outlook

10 Association Watch

12 Energy Efficiency

14 Design Notes

18 Safety

20 Training

22 Conference Preview

56 Product World

60 Ad Index

34

42

May

201

6 Contents | v o l 3 n o 4 | f l u i d p o w e r w o r l d . c o m

26

2015

revenue over $3 million

48

F E AT U R E S

MOBILE HYDRAULICSAg machinery relies on

the versatility of hydraulicsUnique, easily changed designs dominate in agricultural

machines, where the power density and the precision offered by electrohydraulics will

continue to keep farms in the green.

CYLINDERS12 tips for better cylinder selection

Here’s how to design hydraulic cylinders that improve performance, last longer and cost less.

PNEUMATICSA Lego-like solution to customized machines

Building custom vacuum-handling systems from modular parts speeds up design,

reduces costs and improves performance and efficiency.

INDUSTRIAL HYDRAULICSThe hydraulics of injection molders

Precise metering and responsive force control are the name of the game in this specialized

fluid power application.

42

Contents_FPW 5-16_Vs2 MG.indd 6 5/12/16 1:57 PM

10203_YI_FPWMayAd.indd 1 4/27/2016 3:06:24 PMYates 5-16_FPW.indd 7 5/12/16 9:22 AM

Fluid power and smart ironAt the recent Bauma show in Munich, Caterpillar executives unveiled “The Age of Smart Iron,” the company’s strategy to meld machine and digital technology to make con-struction equipment more productive, efficient, safe, sustainable and, ultimately, more profit-able for its customers. “This is not technology for technology’s sake. It is technology that’s focused on solv-ing, and even anticipating, customer prob-lems,” said Caterpillar Group President, Rob Charter. Cat is building hardware and software into components and engines to make equip-ment “smarter,” he explained, for example by capturing vital performance and product-health data and making that information available to customers via the web. Armed with such data, users can make more-informed decisions on how to move material faster while using less fuel, resulting in higher efficiency and lower

cost per ton, he said. Caterpillar already has ap-

proximately 400,000 connect-ed machines and engines

at work around the world, and the aim is that job sites and entire fleets will eventually share data on one common technology platform. Other equipment manufacturers have a similar vision. That brings a heightened focus on what’s being called the “electroni-fication” of hydraulics in construction machinery. Electrohydraulics certainly isn’t new. But digital capabilities and connectivity are becoming essential for integrated systems in mobile equip-ment. It lets hydraulic actuators and travel drives communicate with engines to run more efficiently and lower fuel consumption and emissions. And it’s key to next-generation vehicle mainte-nance programs, where “intelligent” components with built-in sensors trans-mit operating data to machine control-lers and enable functional diagnostics. Fluid-power manufacturers are stepping up their game in light of the new demands. For example, Stage V emissions regulations slated for 2019 will likely mean that engines run hot-

ter. Bosch Rexroth’s new hydrostatic fan drive networks with BODAS

controllers and temperature sensors via a CAN bus to provide cooling on demand independent of engine speed, so engines run cleaner

with less fuel.

8 FLUID POWER WORLD 5 • 2016 www.fluidpowerworldonline.com

K o r a n e ’s O u t L o o k

Ken Korane • Contributing Editor

Danfoss MP1 axial-piston pumps permit connectivity and data capture through a telematics platform for mobile equipment that aids predictive maintenance, remote service, software updates, efficiency management and operator safety. Eaton Pro-FX products interact with machine controls and adapt to chang-ing operating conditions. For instance, CMA mobile valves with embedded electronics and sophisticated software access real-time data like oil tempera-ture and flow, and sense load demand to ensure precise control with low parasitic losses. Parker Hannifin’s IQAN software and hardware provide hydraulic control and data communication. A new Bluetooth device connects the system to a machine CAN bus so technicians can access machine parameters via smartphones and tablets. Or it can serve as a gateway to the cloud for remote support. These offerings merely scratch the surface when it comes to digital-capable hydraulics, and the potential certainly looks unlimited. Curiously, though, few mention cybersecurity. One hopes that IoT professionals and control engineers understand the threats and are well-aware how net-worked devices and machines will impact security. All the benefits will be for naught if hackers and malware exploit machine control systems and million-dollar machines grind to a halt. FPW

Danfoss MP1 pumps use telematics for connectivity.

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ASSOCIATION WATCHASSOCIATION WATCH


The annual Chainless Challenge was held in Irvine, Calif. last month, inspiring eight teams of college

engineering students to redesign a traditional bicycle using hydraulics as the mode of power transmission.

The Challenge was started and supported by Parker Hannifin in 2006, and the NFPA is becoming involved—

and will manage (and broaden) the program in future years.

NFPA to take handlebars of Chainless Challenge

Teams are required to include an accumulator for storing energy, some sort of electronic control system for the bicycle and regeneration technology. The variety of the bicycles built and submitted was fascinating. There were standard bikes, trikes and even recumbent four-wheelers. Accumulators and reservoirs came in all shapes and sizes—and were mounted in a variety of places on the bikes. Some bikes used stainless steel tubing while others went with hydraulic hose. On some, you first noticed a large gearing system while others featured an almost artistic collection of hydraulic fittings. At the Challenge itself, teams competed in three areas: A 200-m sprint race; an efficiency challenge, where bikes were pre-charged and set free without the rider pedaling, to see how much distance they could cover; and a time trial, an endurance challenge that featured three long laps around the runways.

Paul J. Heney • Editorial Director

A total of $20,000 in prize money was awarded. The top four teams were:4. Cleveland State University3. Cal Poly SLO 2. Purdue University1. Illinois Institute of Technology

Winners at individual events at this year’s Challenge were: Illinois Institute of Technology for Innovation/uniqueness of design/originality; Reliability and safety; Cost analysis/prototype and production; and Time trial. Purdue University won for Manufacturability/workmanship and the Meggitt Best paper and presentation. Cal Poly SLO won for the Sprint race and the Efficiency challenge. And Purdue University & Illinois Institute of Technology tied for Best design/team selection.

FPW 5-16 Dept Assoc Watch Vs3 MG.indd 10 5/13/16 9:42 AM

NFPA to take handlebars of Chainless Challenge

5 • 2016 FLUID POWER WORLD 11

ASSOCIATION WATCH

I spoke with two senior mechanical engineering students from the Cleveland State University team, to see what their takeaways were from the program. “I would say there are two things [we learned],” said Steven Rohrar. “Definitely teamwork and project management. Just having a big task given to you and finding a way to overcome it—to really take what your objectives are and either realize them or make them better than what was expected. On top of all that, taking all the theory you learned within your classes from freshman year through your senior year and actually applying them and seeing how it works is kind of a big thing to go into a job and say, ‘I actually know how to do this,’ versus, ‘I know how to do math.’ It was a really great experience.” “Also, when you have a project, things don’t always go how you plan them,” added Jodi Turk.

“Different things break, they don’t perform how you expect, your calculations aren’t actually how it actually reacts. You have to figure out how to change things and make it work.” When asked what they most liked about the program, neither hesitated. “This was actually our senior capstone project,” said Rohrar. “It’s different compared to all the other projects that students from our school are doing. [Other students] are designing something for a specific company for a specific application, whereas here, there are so many different companies represented. It’s just a great networking opportunity.”

Rohrar noted that he had the opportunity to meet CEOs and heads of divisions at companies like Parker during his time in Irvine. And Turk said she enjoyed getting her hands dirty. “I had so much fun; it was a hands-on project where you get to actually design something and build it and then see it work—and then you get to be the one testing it,” she said. “I think this was a great senior design project, I got a lot of experience out of one project: teamwork, complications in your circuits. None of us knew anything about hydraulics when we first started this, so that was cool to learn about all the different components.” FPW

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FPW 5-16 Dept Assoc Watch Vs3 MG.indd 11 5/13/16 9:43 AM


ENERGY EFFICIENCY

Compressed air fail: High compressed air costs at high-end car dealer

Ron Marshall • For the Compressed Air Challenge

A high-end car dealership purchased a premium brand air compressor for its upscale dealership to service both service and body repair bays and the numerous air tools used in the facility. As part of some extra customer service, an air auditor visited the site to assess the new installation. The auditor was impressed with the quality of the high-end equipment, both the cars and air compressor, but especially impressed with the large storage receiver that was installed and thermal mass air dryer that turns itself off between cycles, saving power. But a review of the compressor’s hour meter readings revealed some trouble. Of the 3,300 hours the machine had been running, only 300 hours had been loaded. This meant the machine was running unloaded, still consuming about 35% of its full load power, but producing no air, more than 90% of the time.

Further to this, the compressor room designers forgot that compressors generate heat. One small open window was the only source of cool outside air—and the room temperature was approaching 120° F, even with light compressor loading. It was also discovered that the compressor was left to run continuously, even at night and on weekends, when nobody was working in the dealership. Luckily, the compressor had a smart control that, if enabled, could completely shut the machine off between load cycles if the compressor was lightly loaded, which was most of the time. The dealership also had staff who could turn the compressor off before they left at night. A new compressor operating schedule was implemented, and with a few pushes of the panel buttons the auto shutdown feature was activated, saving the dealership more

than $7,000 per year in electrical costs. A new ventilation system is in the planning stages. The car dealer is an expert in optimizing the operation of vehicles, not air compressors. However, his compressor supplier should have known better. That company had dropped the ball as far as helping the customer get the most out of some pretty nice equipment. Learn more about compressor control in our next Compressed Air Challenge seminar in your area. Visit www.compressedairchallenge.org for more information. FPW

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www.fluidpowerworld.com 5 • 2016 FLUID POWER WORLD 15

DESIGN NOTES Edited by: Mike Santora • Associate Editor

As the control block contains all necessary functions, mobile machines can be upgraded or retrofitted. There is no need to readjust the transport position of the bucket or the boom.

Pitching vibration damping for wheel loaders

Over the years, driving speeds

of construction vehicles have steadily

risen. Even the small- and medium-sized

machines for material handling and

transport (wheel loaders and telescopic

loaders) have followed this trend. Today,

operators reach speeds of over 30 km/hr

when driving on roads.

If a wheel loader drives over a bump, the resulting shock is transferred from the tire to the chassis, setting the mass of the boom in motion. This results in dangerous oscillation that can also compromise the safety and handling performance of the machine. In addition, transport goods may be hurled out of the bucket. Due to the constructional design and the weight sharing of a wheel loader, damping should ideally take place at the cylinders between the boom and the base vehicle to reduce the effect of the introduced pulse so that the resulting pitching motion of the vehicle remains in the controllable area of the driver.

Spatially optimized systemsFor unsprung mobile working machines, the design team at ARGO-HYTOS created vibration damping systems in different designs and feature combinations. All they have in common is the fact that the movement of the bucket or boom is decoupled from the vehicle through hydraulic accumulators. Pipe rupture protection and constant accumulator pre-charging can be integrated just as accumulator safety valves

and other engineering topics atwww.engineeringexchange.com

Discuss This


and drain valves. The individual functional modules can be combined to a specific control block that can be integrated into existing hydraulic systems. The installation can be designed both for series production as well as for retrofitting. In most cases, no changes are needed with the existing hydraulic circuits. From the simple adding of accumulators over systems with adaptive accumulator pre-charging, up to fully integrated systems with pipe rupture protection, anti-cavitation, load-dependent damping and accumulator charging can all be designed.

Uncomplicated conversion or retrofittingAs the control block contains all necessary functions, mobile machines can be upgraded or retrofitted. There is no need to readjust the transport position of the bucket or

the boom. The manifold does not create additional internal leaks. All that is needed to activate the damping is an electrical signal, generated depending on the speed or the operator. Additionally, because there is less wear on the machine material, the vibration damping systems also contribute to the longevity of the machine and thus help minimize total cost of ownership. FPW

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Linear position sensors help cylinders control air and fuel in blast furnaces and power plants

16 FLUID POWER WORLD 5 • 2016 www.fluidpowerworld.com 5 • 2016 FLUID POWER WORLD 17

DESIGN NOTES

A popular application for linear position sensors is hydraulic cylinder position feedback for valve actuators. The position sensor is installed into the back end of the cylinder. The sensing element rests in a cavity that has been gun-drilled through the piston and cylinder rod, extending the full length of the mechanical stroke. A magnet ring is then used as position marker and is recessed into the face of the piston and secured with screws or snap rings. When Balluff began designing one such design—its Micropulse linear position sensors—there were challenges that needed to be dealt with.

To tolerate the harsh operational conditions in these plants, cylinder position sensors must be able to withstand elevated levels of heat and continue functioning reliably. They must also be well sealed against liquid ingress across a wide range of temperatures and humidity, since many installations are exposed to seasonal outdoor weather conditions. During the product design phase, the Balluff design team used a destructive test regimen called HALT (Highly Accelerated Life Test). This test subjects the sensor to rapid swings from extremely cold to extremely hot while

simultaneously applying severe mechanical shock and vibration. The severity of the test conditions is increased until a failure occurs. The failure is then analyzed and the root cause determined. This failure mode is then addressed in the next design iteration with the goal of eliminating it or hardening the product to improve the survivability at even more severe stress levels.

Hydraulic cylinders drive flap and valve operation In any combustion process designed to produce large volumes of heat energy, efficiency and temperature control depend on the amount and proportion of intake combustion air and fuel being consumed under varying conditions of demand. Exhaust or “flue” gases must be managed as well, depending on whether they need to be bypassed to another process or sent to an emissions scrubber before being vented to the atmosphere. For example, in steel production and in conventional electric

A hydraulic cylinder with a linear position

sensor controls the position of a valve to

regulate the flow of combustion air

entering a blast furnace producing iron.

Edited by: Mike Santora • Associate Editor




Discuss This

Illustration showing arrangement of hydraulic cylinder and

linear position sensor on the combustion air valve.

power generation plants, combustion air intake dampers and natural gas valves are controlled by hydraulic cylinder actuators. To regulate damper or valve position, the position of the cylinder must be monitored by a sensor that provides a feedback signal to the process control system. Micropulse linear position sensors are installed into the hydraulic cylinder actuators where they detect the position of a target magnet mounted to the face of the cylinder piston. A linear position sensor is first and foremost a measurement device. It must provide an accurate and stable position signal across a wide range of adverse operating conditions. It’s one thing to create a measurement sensor that performs well in a laboratory, but it takes development and know-how to deliver a sensor that is both accurate and physically robust enough to stand up to adverse industrial conditions. FPW

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lbs.indd 1 2015-09-25 1:58 PM



J. Eric Freimuth • Hydraulic Training AssociatesSAFETY

Most fluid power literature is written for product information only, despite the fact that the sale of fluid power components in the world market is in the billions. Hydraulics has little recognition for being an occupational hazard. Hydraulics is not recognized as a licensed trade nor listed as an occupation, however 25% of occupations are exposed to hydraulics. Safety knowledge and respect for the hazards of hydraulics can only be gained through training and mentoring; however, the practice of “learn as you go” is an unacceptable way to gain safety knowledge. Even though electrical components meet standards, when they are assembled into a circuit, the circuit must be inspected to meet codes of the local jurisdiction. For hydraulic circuits there are no inspections required—

When is the last time you sat in on a hydraulic safety awareness class?

Understanding the hazards of all high-pressure hydraulic systems, such as hose use and maintenance, is critical to ensure safety for your personnel.

nor are there any bodies that carry jurisdiction or authority to do so. Many occupations, such as heavy equipment mechanics, equipment operators, electricians, pipe fitters, loggers and fisherman, work with hydraulic equipment and components daily. Millwrights and heavy-equipment mechanics are the closest recognized trades that incorporate the study of hydraulics in trade schools, and yet mechanics in 25% of occupations are subject to stored energy daily. Of the licensed trades, millwrights and heavy-equipment mechanics may have the highest exposure to hydraulic systems, followed by operators, pipe fitters, electricians and ironworkers. A solid hydraulic safety awareness program is the only way to bring awareness of hydraulic hazards in all areas of the

discipline. Courses should touch on the following areas of importance, each area having sections that relate to any piece of equipment or system: • health and exposure • ethics and standards • hoses • stored energy • threads and porting • seals • safety devices • bleed down • mechanics and geometry • welding • hazard assessment • beyond lock-out • environment • ethics

Imagine a 90% reduction in size and weight.

The patented Cyclone Hydraulic Reservoir is designed to rapidly remove air from hydraulic fluid. The result? Weight and size reduction, along with corresponding savings in fluid expense.

cyclonehydraulics.com

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SAFETY

For example, in the first section, health and exposure, courses should cover the following: • What are hydraulic fluids? • What are the three most common types of hydraulic fluid used in systems today? • What are the things that should be considered when exposed either through penetration or fluid spray? • What are the four main hazards associated with hydraulic fluid? • How can you ensure that the personal protective equipment you have is compatible with specific hazards?

In the end, the best way to prevent exposure to hydraulic fluids is to avoid them as much as possible.

By ignoring or neglecting the hazards of stored energy, we are allowing our workers to be subjected to potential injury or even death. Knowledge of the components is vital to understanding how they work, but the understanding of the dangers will help to prevent these injuries if we pursue the training and safety briefings along with the others safety meetings companies have every day. Isn’t it time we address this subject to all operators and mechanics working around stored energy daily? Training is available to assist companies in developing proper safety understanding in the field of stored energy of hydraulics. FPW

Hydraulic Training Associates htahydraulics.com


Discuss This

Imagine a 90% reduction in size and weight.

The patented Cyclone Hydraulic Reservoir is designed to rapidly remove air from hydraulic fluid. The result? Weight and size reduction, along with corresponding savings in fluid expense.

cyclonehydraulics.com

FPW_Safety 5-16_Vs3 MG.MD.indd 19 5/13/16 10:00 AM

TRAINING


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

Piping and fittingsIn the last article we discussed breaking the hydraulic circuit into three sections. Now, we will discuss one of the options to what con-nect the three sections of a hydraulic circuit—piping. Steel pipe is commonly used as a fluid conductor especially

when large volumes of fluid are moved or when the cost relative to the use of tubing is considered. The basic hydraulic circuit uses

seamless carbon steel piping. It is of the utmost importance that attention to detail be used when selecting piping to be used

in your circuit, and that all piping be free from all dust, rust and all residual left over from the manufacturing pro-

cesses. Because steel is subject to rusting, the pip-ing has a standard finish of a lacquer coating to

protect the metal surfaces, especially during shipping and storage. This process is known

as “black iron pipe.” Pickled and oiled or pickled only are the preferred finish for

hydraulic system piping. It is important to remember that galvanized pipe is

not recommended for use in hy-draulic systems, therefore should never be used.

When sizing a pipe one should remember that the

“Nominal Pipe Size” (NPS) is the system that is used.

For pipes up to 12 in., the inside diameter

is smaller than the outside diameter.

For example, a pipe with a 5-in.

ID would have an OD of 5.5

in. For in. For pipe

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

sizes greater than 12 in., the NPS refers to the OD. For example, a 13-in. pipe will have a 13-in. ID. Commercial grade carbon steel pipe comes in standard sizes 1⁄8 to 42 in. Each pipe size is available in a variety of wall thicknesses. Because the specified OD is standard and remains constant, a thicker wall thickness will change the pipe ID. When selecting pipe for specific applications, the wall thickness must be considered to allow for proper fluid flow. Improper pipe ID will create a large pressure drop in that section of piping. Remember, whenever you have a pressure drop without any work being accomplished, you will have an increase in heat.

Wall thickness is expressed as a schedule number, otherwise known as pipe weight. NPS 1 inch: • Light Wall: schedule #10 • Standard: schedule #40 • Extra Strong: schedule #80 • Extra, Extra Strong: Schedule #160

Schedule #40 is the most commonly used for hydraulic systems at most plants because of its availability and has the minimum wall thickness needed for use in a hydraulic system.

FittingsI often ask my students why they install flanges and fittings in any system. When I explain that the installation of flanges and fittings in a system is for our benefit, I get a puzzled look. Flanges and fittings will give us access to parts of a system without having to cut and dismantle sections to acquire access to that part of the system. They just make our job easier. The attention to detail when work-ing with flanges or fittings is just as important as the attention to detail we pay the piece of equipment we are removing for repair.

Pipe fittings are made in a variety of materi-als. Forged steel fittings are the most suitable for use in hydraulic applications. Fittings are attached to the pipe by: • welded joint: socket weld, butt weld • threaded fitting: screw thread

Welded joints are more commonly used where higher pressures and vibration are present, where the transition between the pipe and fitting must be smooth and where oil leaks cannot be tolerated.

The socket weld is usually used for pipes 2 in. and under, and are produced in three pressure designations: • Class 3000 • Class 6000 • Class 9000

Pressure and temperature ratings for each of the above class fittings are equal to the following schedule pipe: • Class 3000 schedule 80 weight XS • Class 6000 schedule 160 • Class 9000 weight XXS

The butt weld is used for larger size pipes, and it is required to have identification markings on each fitting.

Butt weld fitting identification is as follows:

Example: ABC 6 in. STD WPB 14N2 • ABC: manufacturers’ name • 6 in.: size • STD: schedule or wall thickness • WPB: material designation • 14N2: melt identification or lab control number

Threaded fittings are most common and are used on smaller pipe sizes with pressures up to 2,500 psi.


Piping and fittings


Discuss This

Forged steel threaded fittings are produced in one of the following three pressure designations: • Class 2000 • Class 3000 • Class 6000

Pressure and temperature ratings for each of the above class fittings are equal to the following schedule pipe: • Class 2000 schedule 80 weight XS • Class 3000 schedule 160 • Class 6000 weight XXS

Pipes can only have male threads because the wall thickness varies. The pipe thread form used for pressure joints in North America is the American National Standard Taper Pipe Thread (NPT).

The NPT taper has a 1-in. 16 taper (3⁄4 in. per foot) on the diameter and a 60° thread form. FPW

DMAR Technical Trainingdmartechtraining.biz

TRAINING

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Mary C. Gannon • Managing Editor


The

The inaugural Fluid Power Technology Conference, presented by Fluid Power World

(FPW), will be held at the Milwaukee School of Engineering’s Kern Center Tuesday and Wednesday, June

21 and 22. This marks the first conference the FPW team has embarked upon and brings experts and

users together at the one of the nation’s most innovative fluid power universities.

The majority of technical seminars will be led by MSOE Fluid Power Institute (FPI) and Professional

Education and Research Development (PERD) faculty, as well as Carl Dyke, founder of CD Industrial

Group and a Contributing Editor to FPW. Finally, several sponsors will be offering insight into specific

technologies and applications throughout the two-day event.

debuts in MilwaukeeFluid Power Technology Conference

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C O N F E R E N C E P R E V I E W


debuts in MilwaukeeTuesday, June 21Optional Tours (see sidebar on pg. 24 for descriptions)9:00-10:00 and 10:30-11:30—Grohmann Museum, the Fluid Power Institute and Rapid Prototyping Center

Main Stage1:00-1:45 p.m.—Opening keynote: Cutting-edge mobile hydraulic design—Presented by Aleksandar Egelja, Engineering Manager–Advanced Engineering, Caterpillar. In his presentation, Egelja will discuss his team’s design and development of the 336EH hybrid excavator, as well as lessons learned. He will also describe where the technology is headed and what design engineers should know about the mobile hydraulic systems of tomorrow.

2:00-2:45—The myth buster: Cyclone Hydraulics—Presented by Terry Glidden, Managing Director, and Bob Doll, Senior Application Engineer, Price Engineering. This session introduces the Cyclone Hydraulic Reservoir, which permits engineers to size reservoirs that are 20 times smaller than traditionally sized/shaped reservoirs. This provides space and weight savings for engine components and/or additional load capacity to help comply with Tier IV requirements.

2:45-3:30—How to maintain and troubleshoot hydraulic systems—Presented by Carl Dyke, CD Industrial Group. Dyke will present common component and system faults and logical methods

for zeroing in on a fault. How symptoms are analyzed and clues are gathered will be reviewed from a perspective of knowing and measuring normal system performance. Learn methods for system maintenance that keep unplanned faults to a minimum.

3:30-4:15—Virtual prototype through dynamic simulation—Presented by Céline Cabana of FD-GROUPS America, North American subsidiary of FLUIDESIGN Group. This session will help define when and where dynamic simulation can be applied. Project examples will be used to determine the correct parameters when considering the use of multi-domain dynamic simulation for problem solving and new developments. Benefits of building a virtual prototype will be discussed in detail.

4:15-5:00—Properly applied electro-hydraulic components—Presented by Tim Kerrigan, Assistant Director, FPI. On-Board Electronics (OBEs) can make a hydraulic system cleaner and simpler. But electrical devices and OBEs must be appropriate for the application, or they can become a maintenance nightmare. With the appropriate electrohydraulic components for a given application, the hydraulic system can be the ideal situation.

Breakout Stage2:00-2:45—Properly applied cooling for hydraulic systems—Presented by Tim Kerrigan, Assistant Director, FPI. Kerrigan will address the pitfalls and challenges of achieving the appropriate cooling design for hydraulic systems. Critical factors of loading duty cycle, ambient conditions, heat exchanger design, coolant and more will be discussed.

2:45-3:30—Optimizing your hydraulic cylinder designs—Presented by Milwaukee Cylinder. This session will highlight a variety of options one must consider when selecting hydraulic



Get an inside look at MSOE and the FPI C O N F E R E N C E P R E V I E W

cylinders. Attendees will learn ways to to systematically analyze and design systems to remove risk for SIL Level 3 Certification. The presenter will also address high-temperature applications and how to optimize RFID with tie-rod cylinders for fast and easy maintenance.

3:30-4:15—Pneumatics maintenance and troubleshooting—Presented by Carl Dyke, CD Industrial Group. Maintenance personnel will gain an understanding of pneumatic principles, component design and function. Attendees will learn how to identify and explain actuators; pneumatic circuit and electro-pneumatic designs; apply logical steps in trouble-shooting; and analyze air-over-oil circuit design and vacuum system diagrams for diagnosis and troubleshooting.

5:00—Cocktail hour and networking, Exhibit Floor

Wednesday, June 227:30-8:30—Breakfast, Exhibit Floor

Main Stage8:30-9:00—Keynote presentation: Modern efficiencies, technological advances and sustainability in fluid power—Presented by Thomas Price Jr., CEO, Price Engineering. Price will highlight the opportunities in fluid power as they relate to advancing technologies of tomorrow. He will provide insight into sustainable and efficient fluid power solutions that our industry should consider for our future.

9:00-9:30—Q&A/Break

9:30-10:15—Roadmap to an application-specific hydraulic cylinder—Presented by Tony Casassa, Aggressive Hydraulics. Learn how to opti-mize operating pressure based on force requirements and overall system configuration; select mounting style, including unusual and non-standard mounts; explore integrated linear position sensors; review integrated cartridge valve manifolds and environmental exposure; and more.

10:15-11:00—The value of the fluid power distributor in a changing world—Presented by Bill Tulloch, Executive VP of Flodraulic Group. The term “distributor” has taken on new meaning. It’s no longer about “moving boxes” through the supply chain efficiently. Tulloch will present the value of the continually evolving role of the fluid power distributor as an integral member of the manufacturer’s marketing team and customer’s engineering team.

11:00-11:45—Common QD issues and their solutions—Presented by CEJN North America. This session will address common QD (Quick Disconnect) obstacles for hydraulic applications, such as issues with connection under residual pressure, connecting multiple lines efficiently and ways to resolve these issues.

11:45-1:00—Lunch and networking, Exhibit Floor

1:00-1:45—Rapid reverse engineering for legacy parts—Presented by Joe Munski, Fluid Power Test Engineer, FPI. This session will discuss the proper application of 3D scanning for retrofitting applications. Typical

Attendees will have an opportunity to participate in optional tours before the conference begins on Tuesday morning at 9 and 10:30 a.m. Space is limited, so sign up quickly. Tours include the following:

Fluid Power Institute—For more than 50 years, FPI has been a leader in fluid power research and education by providing practi-cal integrated solutions for fluid power components and systems to world renown manufacturers, OEMs, distributors, users and the U.S. DOD by using experienced faculty, staff and students. FPI has three major focus areas: Engineering Services, Tribology Services, and Test and Evalua-tion Programs. FPI’s campus lab facility has various hydraulic power units and test systems that can readily be configured to run a wide variety of test procedures and protocols.

Rapid Prototyping Center—The RPC is an industrially sup-ported laboratory focused on additive manufacturing/3D

printing technology. RPC has the resources and 25 years of hands-on experience to

apply to your challenges. Whether you need a functional prototype or insight into new manufacturing processes, the center provides additive manufactur-ing services, applied research, product/

process development support, and educational services for its 40+ industrial

consortium members.

The Grohmann Museum—Named in honor of Dr. Eckhart Grohmann, an MSOE Regent, Milwaukee businessman and avid art collector, who donated this collection to MSOE in 2001 and subsequently the funds to purchase, renovate and operate the museum, The Eckhart G. Grohmann Collection “Man at Work” comprises more than 1,000 paintings and sculp-tures from 1580 to the present. They reflect a variety of artistic styles and subjects that document the evolution of organized work.

Finally, all attendees will have opportunities to connect with presenters, sponsors and FPW staff in the intimate exhibit space—as well as a cocktail hour Tuesday evening following the final presentation. Sponsors include: Aggressive Hydrau-lics, CEJN, Delta Computer Systems, FD Groups America, Flo-draulic, FluiDyne, Grimstad, HED Intelligent Vehicle Controls, International Fluid Power Society, Lynch Fluid Controls Inc., Milwaukee Cylinder, OEM Controls Inc., Price Engineering, SMC and Webtec.

Visit www.fluidpowertechconference.com for a complete schedule and to register.



C O N F E R E N C E P R E V I E W

driving decision factors for the replacement selection are fit, form and function. 3D modeling addresses the “fit” while we use 3D scanning of legacy components and systems in situ.

1:45-2:30—Cyclical testing in fluid power applications: Why frequency matters in sinusoidal testing—Presented by Peter Nachtwey, President of Delta Computer Systems. Cyclical testing is of growing importance for documenting life cycle data on items such as tools, verification of product components or cylindrical medical gas containers. While virtually any curve profile or cyclical pattern can be used during testing, this presentation will focus on sinusoidal testing and the practical limitations of sine wave use.

2:30-2:45—Break

2:45-3:30—Electrohydraulics troubleshooting and motion control—Presented by Carl Dyke, CD Industrial Group. Propor-tional valves, servovalves and fine motion control systems offer unique challenges. Emphasis will be on the internal workings and normal operating characteristics of complex valves, making system adjustments, maintenance checks for proper operation, and troubleshooting tips.

3:30-4:15—System modeling and simulation—Presented by Dr. Medhat Khalil, Director of PERD. This session focuses on the technique of building mathematical models with the least amount of design parameters to help application engineers involved in modeling systems. The adopted modeling process of a component is based on existing data published by the component’s manufacturer. If the data is missing, the presentation discusses how to identify the dynamics experimentally.

4:15-5:00—Closing keynote: Importance of contamination control in hydraulic systems—Presented by Tom Wanke, CFPE Director of the FPI. About 70 to 80% of hydraulic system failures result from contaminants in the hydraulic system. This presentation will cover the types, sources and effects of contaminants on hydraulic components and systems. Methods and technolo-gies will be discussed to eliminate, reduce and/or control contamination levels for improved reliability and optimal performance.

Breakout Stage10:15-11:00—Energy saving in pneumatic systems—Presented by Douglas Lauer, CFPPS, Product Specialist SMC. This session will define and explain the benefits of energy conservation, define areas where energy conservation can be applied and realize energy saving opportunities. Attendees will learn how to monitor air flow and target areas for savings, such as actuators, fittings and tubing.

11:00-11:45—Advanced mobile with load sense hydraulics—Presented by Carl Dyke, CD Industrial Group. This course is designed for personnel who are charged with the care of mobile equipment with load sensing hydraulic systems. Animations and interactive simulations will be used as this session looks at load sensing hydraulic system functions, and how to test, adjust and troubleshoot them.

11:45-1:00—Lunch and networking, Exhibit Floor

1:45-2:30—Leveraging TPM (Total Proactive Maintenance) in maintenance of fluid power equipment—Presented by Kate Kerrigan, Operations Director, Allied Reliability Group. Kerrigan will reveal how to look at future world-class reliability and plan a route to achieve that state by leveraging TPM, no matter where you are starting out, even with less budget, less capital and less man-power.

Visit www.fluidpowertechconference.com to register.

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Ag machinery relies on the versatility of hydraulics


Unique, easily changed designs dominate in agricultural machines, where the power density and the precision offered by electrohydraulics will continue to keep farms in the green.

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

Josh Cosford Contributing Editor

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The agricultural machinery industry

has probably been the slowest evolving sector with

regards to electronic integration. It’s not that machine

manufacturers haven’t kept up to date with the latest

technology; it’s more that the vast majority of farms (by

principle owner, not acreage) are still relatively small.

According to the 2012 USDA Census of Agriculture, of

the 2.1 million principle ownership farms, more than

75% sold less than $50,000 per year, and about 57% sold

less than $10,000 per year. This leaves little room in the

budget for GPS-equipped combines, as you can imagine.

Hydraulics have been absolutely integral to farming since the invention of fluid power. Where industrial hydraulics replaced mechanical machinery, agricultural hydraulics replaced man and beast, saving both warm bodies from injury and increasing productivity exponentially. Because a tractor could and would be anywhere in the hundreds or thousands of acres around a farm, access to any type of electric power was non-existent. If you wanted something done, you needed mechanical motivation or old-fashioned blood, sweat and tears. The advantage of agricultural hydraulics over many decades has been that they are strictly mechanical, having no reliance on even 6- or 12-V tractor electricity. Hydraulics are as easily understood as the PTO on the family farm’s tractor, can be replaced or jury-rigged in the field (literally … in the field). The single fixed-flow, open-center pump supplying flow to a single monoblock valve on 70-year-old Farmall is still something you can find in use on a field today. When machinery is that reliable, and your farm only pulled in $50,000 last year, how can you justify twice that amount for a new model with modern technology?

Unique designs Agricultural hydraulics are unique in many ways. Systems must be versatile and adaptable, because prime movers and supply of input hydraulics vary vastly. You could have a hydraulic pump driven from the PTO of the tractor, or use the hydraulic take-offs from the tractor itself. If the tractor hydraulics is used, it will be either “open center” (fixed displacement pump) or “closed center” (variable displacement pump).



The terms open center and closed center, when used to describe hydraulic valves, refer to the center condition of a directional valve. In the agriculture industry, it simply tells the user or designer that valving is either “pressure-to-tank” in neutral, or “pressure port blocked” in neutral. Which system is used affects the nature of the hydraulics on the implement. Although most of the industry has switched to closed-center, variable pump systems, there are still so many old tractors out there running open-center, fixed pumps. This is why designing machinery for the agriculture industry is so challenging; the one size fits all solution is rare. To get a better idea of the difficulties in designing machinery for the agriculture industry, I spoke with Troy Grose, mechanical designer with Husky Farm Equipment in Alma, Ont., an agricultural OEM specializing in liquid manure processing systems. They build pumping, transferring and spreading equipment of various types, most using hydraulics. Grose explained what makes agricultural hydraulic machines different from other mobile hydraulic applications. “When working with implement-style machinery (towed behind a

tractor), the hydraulic solution supplied must be capable of adapting to any tractor that is connected with it. In many other mobile hydraulic applications, a fixed solution can be designed and implemented specific to that particular application,” Grose said. “Ag equipment differs in that way, as you never know what tractor is going to be used. We can see one tractor capable of supplying 18 gpm and another of 40 gpm. Smaller utility tractors and some older tractors will have open-center hydraulic systems while the newer, larger tractors will have closed-center, pressure compensated systems.

“The hydraulic solutions we provide on our equipment must be able to adapt to these always changing scenarios. The agricultural machine can operate in a fury of harsh environments, making the component selection and design a critical part of the engineering process for a long lasting and durable machine.”

Flexible designs are a must The flexibility required so hydraulic systems can adapt to any tractor is possible and quite simple. I worked on one application with Grose that combined closed-center directional control and accessory valves, which could be operated from fixed or variable pumps up to 60 gpm. The circuit contained a load-sensing network fed into


Wireless and electronic controls on farm machinery, such as this Kar-Tech Compact mini-bellypack wireless transmitter, are quickly becoming standard devices on hydraulic systems rather than optional functions.

Agricultural hydraulics are unique in many ways. Systems must be versatile and adaptable, because prime movers and supply of input hydraulics vary vastly.



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a single, large, load-sensing pressure compensator. Based on the required flow at each actuator, the compensator would send only the flow required (from 2-60 gpm) to the circuit, and dump the unused flow back to tank. It was essentially a load-sensing unloading circuit. Because you could load sense with a fixed pump, it would work with any pump, including a load-sensing pump. To convert to usage with a variable displacement pump, the compensator is simply removed and a cavity plug put into its place. This would negate the need for the load sense check valves, but they would not harm anything by being left in place. However, should a load-sensing pump be added as the supply, the load sense network could be tapped into from an auxiliary load-sensing port on the block. There was no hydraulic input below 60 gpm that this manifold could not have been used with.


Electronics are the wave of the future I’m always curious where fluid power industries are going, especially with the changing global markets, so I asked Grose what he sees for the future of agricultural hydraulics, to which he responded, “Every-one in the ag industry knows what mono-block valve banks and tie rod hydraulic cylinders are, and those won’t be disap-pearing anytime soon, but we are seeing a shift to solutions that provide the operator with automated and easier to use systems,” he said. “Wireless control and electronic operation of these systems is undeniably already a dominant part but we will con-tinue to see more equipment coming along with these installed as standard rather than optional features.” Electronics have already proliferated in industrial applications and are quickly becoming a crucial part of agricultural machinery, too, albeit at a slower pace.

A close-up look at a hydraulic valve manifold for a Husky piece of agriculture equipment.


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“Electronics have already become an integral part of the hydraulic system for us. We are supplying wireless remotes to control monoblock valves where the operator doesn’t have to get out of the tractor seat to operate other functions in a completely separate tractor,” Grose said. “In our mobile truck-mounted tank division we sell a hydraulic manifold that can adapt to any truck it is mated to with up to 60-gpm input flow, and all directional valves are controlled electronically by the operator in the cab. In this same application we are controlling the ramp up and down speed and maximum flow to hydraulic motors electronically; their values are adjusted electronically. “We are also seeing a shift to GPS mapping systems where application rates are controlled electronically from the tractor. Tractors are able to use mapping



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systems and auto-steer to have their tractor drive exactly where they want it to go, and rate apply the product to the field all done with virtually no operator input once the setup is complete,” Grose continued. “These systems are integrated into the tractor through ISOBUS (ISO 11783), which is becoming a more standardized interface between implement and tractor. The standardization of interfaces like ISOBUS are a necessary part to ensure that all our implements can talk to each tractor regardless of what color the tractor is. With integrated systems between the tractors mechanical functions, GPS, hydraulics, and the implements it tows, there will be endless possibilities to where electronics are going to take us in the future.” I firmly believe electrical actuators will never replace hydraulics on mobile machinery, but I also agree with Grose’s



Discuss This


sentiment that electronics will have in increasing share of control function of hydraulics, whether they are on an injection molding machine or manure spreader. I also believe manually controlled hydraulics will have a home for decades to come, as farmers love to feel a mechanical lever under their gloved hands. So don’t put that Farmall in a museum just yet. FPW

We are also seeing a shift to GPS mapping systems where application rates are controlled electronically from the tractor.

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C Y L I N D E R S


Bosch Rexroth builds large hydraulic cylinders with bores to 1.5 m and strokes to 24 m.

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Hydraulic cylinders harness fluid pressure

and flow to generate linear motion and force, and they

work well in both industrial machines, like presses

and plastic-molding machines, and in mobile equip-

ment, like excavators and mining trucks. And when

compared with pneumatic, mechanical or electric

linear-motion systems, hydraulics can be simpler,

more durable and offer significantly greater power

density.


tips for better cylinder selection

Marty Hegyi Product Manager, CylindersBosch Rexroth Corp.

Here’s how to design hydraulic cylinders that improve performance, last longer and cost less.

twelve


Hydraulic cylinders are available in an impressive array of types and sizes to meet a wide range of application needs. Choosing the right cylinder is critical for maximum performance and reliability. Here are 12 practical tips for selecting, sizing and operating the best one for a job.

Selection considerations

1 Choose the right cylinder type. Two basic hydraulic cylinder designs for industrial applications are tie-rod and welded cylinders. Tie-rod cylinders use high-strength threaded steel tie rods on the outside of the cylinder housing for additional

strength and stability. In the U.S., this is the most common cylinder type. They’re used on most general industrial applications, such as plastics machinery and machine tools, although they tend to be limited to 3,000 psi maximum operating pressure. The cylinders are built to NFPA stan-dards, which makes their dimensions and pressure ratings interchange-able with any other cylinder built to that standard. Welded or mill-type cylinders have a heavy-duty housing with a barrel welded or bolted directly to the end caps and require no tie rods. Designed for higher pressures, to 5,000 psi or greater, they are generally preferred in more-rugged applications such as presses, steel mills and offshore settings with harsh environments and wide temperature swings. Unlike U.S. OEMs, European manufacturers typically use mill-type cylinders in almost all general industrial applications. (They also use tie-rod cylinders, but generally for lower-pressure tasks up to 160 bar (2,350 psi).) However, due to the design, tie-rod cylinders are less expensive than mill-type cylinders—another reason for widespread use in the U.S. Also keep in mind that cylinders are often customized. NFPA cylinder standards dictate dimensions, pressure ratings, type of mount-ings, and so on—they’re standard catalog products. However, engineers designing custom machinery often need to deviate from the standards with special mountings, port sizes or configurations to suit a particular application. About 60% of the cylinders sold in the U.S. are catalog items, while 40% are modified products with unique requirements.

2 Select the proper mountings. Mounting methods also play an important role in cylinder performance. The cylinder mounting method first depends on whether the cylinder body is stationary or pivots. For stationary cylinders, fixed mounts on the center-

line of the cylinder are usually best for straight-line force transfer and minimal wear. Among the different variations, flange mounts are gener-ally preferred. Loads are centered on the cylinder and opposing forces are equally balanced on rectangular or round flanges. They’re strong and rigid, but have little tolerance for misalignment. Experts recommend cap-end mounts for thrust loads and rod-end mounts for pull loads. Centerline lug mounts also absorb force on the centerline, but require dowel pins to secure the lugs to prevent movement at higher pressures or under shock conditions.

C Y L I N D E R S


Sizing software for cylinders is a great tool, but

more engineers need to take advantage of the benefits

it offers. These programs address most, if not all, of the

pertinent questions designers need to answer to spec the

right cylinder.

One such program developed by Bosch Rexroth is the

Interactive Catalog System (www.boschrexroth.com/ics).

It lets users enter parameters like force, pressure, load,

angle of installation and mounting type, and the software

sizes the cylinder, lists variations that meet the criteria and

offers possible alternatives. It also lets engineers select

and test cylinders on-screen before specifying the actual

components. In addition, ICS generates dimensional draw-

ings and 2D or 3D models for direct import into AutoCAD

or other CAD software.

Don’t overlook sizing software


C Y L I N D E R S

Side-mounted or foot-mounted cylin-ders are relatively easy to install and service, but they generate offset loads. The mounts experience a bending moment as the cylinder applies force to a load, potentially increasing wear and tear. Heavy loading tends to make long-stroke, small-bore cylinders unstable.


Side and foot mounts need to be well aligned and on the same plane, and the load supported and guided. Other-wise, induced side loads due to misalign-ment lead to cylinder wear and seal leaks. Engineers also must be concerned with shear forces on the bolts. Add a

dowel or shear pin and keyway behind the feet to prevent the forces from po-tentially shearing the mounting bolts. If necessary for extra support, add another set of foot mounts in the cylinder mid-section in addition to those on the head and cap ends.

Mill-type cylinders have a heavy-duty hous-ing with a barrel welded or bolted directly to the end caps and require no tie rods.



3 Select the right pivot mountings when the cylinder body moves. Pivot mounts absorb force on the cylinder centerline and let a cylinder change alignment in one plane. Common types include clevis, trunnion and spherical-bearing mounts.

Clevismountscanbeusedinanyorientationandaregenerallyrecommended for short strokes and small to medium-bore cylinders. Cylinder engineers prefer clevis mounts with spherical bearings over those with plain bearings because they allow for a bit more misalign-ment and are, thus, a bit more forgiving. However, if using a spherical bearingonarearclevis,theyalsorecommendarod-endattachmentthatpivots—suchasasphericalrodeye.Thecombinationhelpscom-pensateforanysideloadingorpotentialmisalignment. Trunnion mounts come in head, mid and rear-mount versions. Themid-trunniondesignislikelymostcommon,asitoffersdesignersabitmoreflexibility.Theycanbespecifiedexactlyinthecylindermid-sectionormostanywheretowardthefrontorrearastheapplicationdemands.Oncespecified,however,themountisnotadjustable.

Sizing considerationsFor all types of cylinders, important parameters include stroke, bore diameter,roddiameterandpressurerating.

4 Piston-rod diameter is critical. Perhaps the most common error in hydraulic design is underspecifying the piston rod, making a cylinder more prone to stress, wear and failure. Piston-rod diameters can range from 0.5 to more than 20 in., but they must be sized for the available loads. In

apushapplication,itisextremelyimportanttosizetheroddiameterproperly,basedonEulercalculations,toavoidrodbucklingorbending. When designing a cylinder to generate a required force, sizing the rodisalwaysthefirstconsideration.Fromthere,workbackwardanddetermine bore size for the available pressure, and so on.

5 Prevent rod bending. In cylinders with long strokes, a fully extendedrodcanbendunderitsownweight.Excessivebending leads to wear and damage to seals and bearings. It could even cock the piston inside the bore, which can score and damage the inner surface of the cylinder. Rod

deflectionshouldneverexceed1to2mm. Cylinder rods that are at risk for bending or misalignment require additionalsupport.Dependingonthestrokelength,astoptube—which increases the bearing area of the cylinder—may be required to preventexcessivewearandjack-knifing.Engineersmightalsoconsidera larger diameter rod, which increases strength. But that also increases weightandmaybeself-defeating,sodothemathcarefully.Inextremecases,usersmayalsoneedtoaddexternalmechanicalsupportfortherod, such as a saddle-type bearing.

C Y L I N D E R S


Rugged mill-type cylinders with pivot mounts stand up to harsh outdoor mine conditions.


6 Watch out for impact loads. Stroke length, the distance needed to push or pull a load, can vary from less than an inch to several feet or more. But when the cylinder extends or retracts, ensure that the piston doesn’t bottom out and generate impact

loads at the end of stroke. Engineers have several options: Add internal cushions to decelerate the load near the end of stroke; add an external mechanical stop that prevents the cylinder from bottoming out; or use proportional-valve technology to precisely meter flow and safely decelerate the load.

7 Weigh bore diameter versus operating pressure. To produce a given amount of force, engineers can specify large-bore cylinders that operate at low pressures, or vice versa. Generally, systems that operate at higher pressures but with smaller

cylinders are more cost effective. Also the benefits cascade. Smaller cylinders require less flow and, in turn, smaller pumps, lines, valves and so on. Many installations see an overall cost reduction by moving to higher pressures. That said, cylinders are rated for both nominal (standard) pressure and test pressure to account for variations. Systems should never exceed the nominal rated design pressure of a cylinder.

8 Add a factor of safety. While design calculations are essential, real-world operations differ from theoreti-cal results. Always assume peak loads will require additional force. The rule of thumb is to choose a cylinder with a tonnage rating of 20% more than

required for the load. That compensates for losses like friction from the load, efficiency losses in the hydraulics, actual pressure below the rated system pressure, slip-stick on cylinder seals and bearings, and so on.

Operating considerationsCylinder parameters like stroke and force must match machine requirements, but that is only half the challenge. Environmental and operating demands also play a major part in determining a cylinder’s ultimate success.

9 Match the seals to the job. Seals are probably the most vulnerable aspect of a hydraulic system. Proper seals can reduce friction and wear and increase service life, while the wrong seal leads to downtime and maintenance headaches. It probably goes

without saying, but ensure the seal material is compatible with



Fluidyne 5-16_FPW.indd 40 5/12/16 2:01 PM


the fluid. Most hydraulics use a form of mineral oil, and standard Buna-N seals tend to work well. But applications involving synthetic fluids, such as phosphate esters, require Viton seals. Polyurethane is also incompatible with high water-based fluid such as water glycol. Regardless of the fluid, keep it clean. Contamination and dirt in the fluid will damage seals. It can also score the inside of the barrel and eventually ruin the cylinder. If operating temperatures exceed 300° F, standard Buna-N nitrile rubber seals may fail. Viton synthetic rubber seals generally handle temperatures to 400° F and fluorocarbon seals even higher. When in doubt, assume conditions will be worse than they first appear.

10 Add a gland drain. Probably 90% of cylinder failures are due to the seals. That holds even if engineers specify the proper seals for the fluid, pressure, environment and application as they wear out over time and need replacement. Most

experts recommend that seals should be maintained periodically, rather than waiting for failure at a usually inopportune time. If cylinders are in hard-to-access locations that makes main-tenance difficult, or if leaks will damage products or lead to costly downtime, order cylinders with a “gland drain.” This is a special port machined into the cylinder head between primary and secondary seals; or between primary and rod wiper. Then, if the primary rod seal begins to fail and leak, oil bypasses the seal and flows out the gland-drain port—generally through tubing to a collection bottle. If oil col-lects in the normally empty bottle, it gives a visual indication that seals are wearing out and will soon need replacement. Cylinders usually have a secondary rod seal or a double-lip rod wiper that temporarily prevents oil from leaking out the rod end, giv-ing maintenance personnel time to schedule repairs.

Tie-rod cylinders have high-strength threaded steel tie rods on the outside of the cylinder housing for strength and stability.

C Y L I N D E R S

11Watch the materials. The type of metal used for the cylinder head, base and bearing can make a significant difference. Most cylinders use SAE 660 bronze for rod bearings and medium-grade carbon steel

for heads and bases, which is adequate for many applications. But stronger material, such as 65-45-12 ductile iron for rod bearings, can provide a sizable performance advantage for tough industrial tasks. Also consider extreme temperatures. Typical carbon steels used in cylinder components are generally suited for around –5 to 200° F. In arctic conditions well below 0° F, for example, standard steel can become brittle and may require alternative materials.

12 Protect the rod. Because the piston rod meets the outside environment, it must resist attack from water, salt air, corro-sives, and other harmful substances. In general industrial applications, carbon

steel with chrome plating is the norm. But in wet or high humidity environments, such as marine hydraulics, 17-4PH stainless steel with chrome plating is used for most piston rods. Some cylinder manufacturers offer special protective coatings. Bosch Rexroth, for example, offers Enduroq, which is a proprietary thermal-spray coating or plasma-welded overlay that’s applied to rods for extreme corrosion protection and high wear resistance. It’s used in harsh environments, typically for specialty large-bore, long-stroke cylinders. For dirty, abrasive conditions, engineers have a love/hate relationship with protective rod boots. Installing a boot over the rod keeps out dirt, metal shavings and other external con-tamination that would otherwise damage the rod and eventu-ally the seals. However, if the boot punctures or rips, dirt gets drawn in and may not get out, which is worse than no boot at all. Maintenance personnel must routinely check for worn or torn boots that could accelerate damage to the cylinder. FPW

Bosch Rexroth boschrexroth-us.com


Ken Korane • Contributing Editor

A Lego-like solution forcustomized machines


FPW_Pneumatics 5-16_Vs6_KK MG.indd 42 5/13/16 11:03 AM

P N E U M A T I C S


Food and beverage processors and packagers strive to move goods as quickly, efficiently and safely as possible without damag-ing the end product. Sometimes the work is done by hand, but automated systems are often preferred to speed throughput and ensure quality. Devices like pick-and-place gantries, delta robots, and SCARA pickers work great when handling one piece at a time. But when moving dozens of parts at a time, vacuum “layer” grippers are often a better option. These large-footprint systems mount to handling devices like robots or forklifts and take advantage of the physics of vacuum to cleanly and firmly grip, move and place products precisely where needed. What sets innovative designs apart, however, is how these gripping systems are engineered and built.

Modular benefits Increasingly, package-equipment manufacturers are shying away from expen-sive, one-off systems with long lead times and only suited for a single task; and from standard, off-the-shelf systems that save money but compromise perfor-mance. Instead, design engineers are turning to modular systems as a faster and more-economical approach. These are built from standard components and subsystems, but the end product can be uniquely tailored for size, speed, energy efficiency and, of course, the type of product being moved. In addition, modular units can be quickly changed and adapted to different applications without requiring a major redesign or lengthy lead time. That’s important because speed and flexibility are the main challenges for today’s industrial packaging processes, according to experts at Schmalz Inc., Raleigh, N.C. Research at Schmalz shows that conventionally designed vacuum grippers are bottlenecks in terms of design, assembly and commissioning of customer-specific packaging and handling machines. That’s due to often-complicated processes involving everything from design to start-up.

Independent zones on layer grippers direct vacuum only where needed, minimizing leaks and saving energy.

Building custom vacuum-handling systems from modular parts speeds up design, reduces costs and improves performance and efficiency.

FPW_Pneumatics 5-16_Vs6_KK MG.indd 43 5/17/16 12:27 PM

P N E U M A T I C S

Part of the problem is that packaging-industry OEMs and system integrators create concepts and “digital” versions of machines based solely on technical specifications or process descriptions. In many cases, product samples are not yet available, or they are only prototypes and subject to change. Engineers don’t finalize the machine concept and begin design until an or-der is actually received. And a vacuum gripper is usually only designed after machine details are complete. Ac-cording to Schmalz’s calculations, this can put a lot of challenging require-ments on gripper design. Another issue is that frequent product changes have become the norm in many industries. Depend-ing on the product life cycle or how a product changes in terms of size, shape, weight and feel, different grip-pers must be integrated on the ma-chine. A modular approach lets users combine various flanges, connectors and suction pads to create a “new” end effector with relative ease.

Layer grippers As one successful example, Schmalz has developed the SPZ layer gripper system to streamline pick-and-place, palletizing and depalletizing pro-cesses. According to Mike Vigoda, manager of the company’s Vacuum Gripping Systems Group, the SPZ is a complete system that includes everything from vacuum cups to the vacuum generator, and all the valves, switches, connectors and controls in between. Its flexible “Lego-like” con-figuration lets users quickly and easily tailor the unit to meet exact applica-tion requirements. In packaging applications, Vigoda explained, the SPZ helps automate pick-up and transport processes for


Most universal area grippers that use external

vacuum sources require add-on valves to control vacuum

flow to suction cups and pads. Schmalz’s newest version,

the FMP-S gripper, includes an integrated vacuum-control

valve for a more-compact overall unit. Like FXP and FMP

grippers, it can be used as a standalone device or as a

component on the SPZ layer gripper.

Typical grippers rely on external valves to control

vacuum flow. An additional venting valve and an active

compressed air line are also needed to ensure quick

release of a gripped product. In contrast, the FMP-S

connects directly, via hose or tubing, to the vacuum

source. The vacuum valve, control valve, electrical

connection and air-line connectors are built in.

The result is a more-compact unit with 40% shorter

evacuation times and 25% less weight, compared to

similar grippers with external valves. This makes the unit

well-suited for highly dynamic applications. Packaging the

relevant components internally also improves reliability,

reduces installation costs, and minimizes the possibility of

tooling /robot interference that could otherwise damage

the valve.

The FMP-S gripper with a built-in vacuum-control valve is faster-acting and lighter than units with external valves.

The benefits of built-in valves

items that have been sorted and stacked in layers. The gripping system can handle a wide range of products that include cardboard boxes, com-posite packaging, bottles, cans, glass jars, bags, and shrink-wrapped and loose goods—even chilled and frozen products. (And with different sealing interfaces, SPZ layer grippers can be used for construction materials like wooden boards and beams, ceramic tiles and bricks.) Manufacturers use the SPZ in a number of ways. One is to move a pallet’s worth of empty cans, bottles or plastic containers and place them on conveyors. From there, the containers feed into a high-speed production system, say for filling with peanut butter or mustard. At the other end of the line, grippers move finished products from holding areas and stack them on pallets, one layer at a time. The SPZ also lets manufactur-ers configure the layers as needed for stability, maximum use of space, or other reasons. And the gripping system can handle layers with “chim-neys” or gaps, and those that are in-complete or have a mix of products.

Building blocks Key subsystems for constructing the SPZ are universal grippers called “area-gripping” systems, said Vigoda. They’re versatile, reliable, efficient and suited for a wide range of tasks. Individually, they’re proven grippers designed for handling single parts or just a few items. For larger jobs, mul-tiple area grippers can be interlocked together and networked to build the SPZ. Two types of area grippers are available. One, called FXP, has built-in vacuum generation via a plug-in


Area grippers are used for standalone tasks, and as building blocks in larger layer grippers.

Depending on the product life cycle or how a product changes in terms of size, shape, weight and feel, different grippers must be integrated on the machine.

ejector. The second, the FMP, is similar in construction but interfaces with external vacuum generators like pumps and blowers. New versions, FMP-S and FXP-S, include in-tegrated vacuum valves for more-compact overall units. (See the related sidebar, “The benefits of built-in valves.”) All are built of aluminum for high stiff-ness and low weight. Lower weight often permits higher accelerations for higher pro-ductivity and, possibly, results in smaller ro-bots that mean lower overall system costs. Area grippers each measure about 5.1 in. (130 mm) wide. But users can specify length anywhere from 17.4 to 56.4 in. (442 to 1,432 mm) in standard configurations. Custom units in 5-in. increments for FMP/FMP-S (11 in. for FXP/FXP-S) have a maxi-mum length of 236 in. Thus, choosing the number of modules and the desired lengths lets users specify final SPZ dimensions and overall working area. For instance, they can easily handle standard pallets measuring about 40 × 50 in. (1 × 1.2 m) and carry a maximum load of 550 lb (250 kg). As an added benefit, noted Vigoda, the


interlocking area grippers also let users cre-ate multiple, independent vacuum zones. Rather than powering the entire surface every cycle, users can selectively direct vacuum only to specific areas as needed—say for moving a half-pallet of goods. That ensures minimal leakage and higher energy efficiency. One SPZ could have two, three, four or more different size and shape suc-tion zones. To create the zones, a controller or PLC directs onboard valves to selectively control vacuum flow. However, multiple zones do require more I/O. In addition, vacuum switches supply feedback to the control-ler. They are used to check vacuum levels, determine part presence or signal a fault, letting the controller initiate the next move or halt a process. Also, users can opt for on-board or external vacuum generation. Built-in, venturi-type units generate vacuum with compressed air, and they are generally for smaller, lower-cost SPZ systems. For larger designs, said Vigoda, it usually makes sense to use an external vacuum blower. That’s


P N E U M A T I C S

46 FLUID POWER WORLD 5 • 2016 www.fluidpowerworld.com 5 • 2016 FLUID POWER WORLD 47

Vacuum layer grippers like the Schmalz SPZ can move dozens of products at once.

New VSi series of vacuum and pressure switches from J. Schmalz GmbH lets handling systems communicate with conventional fieldbus systems via IO-Link and also supply readout information to smartphones. Electronic VSi switches monitor pressure in automation and handling systems and transmit status data to a controller via the IO-Link interface. It gives system operators better access to operating parameters and diagnostic data and quicker

response in the event of faults or errors. The switches come with or without a display, or with an external operating display; and in pressure, vacuum or combined versions. Units can be installed independently of the display,

for instance directly on a suction pad. Settings like switching points can be adjusted via the display

element and transferred to other switches. Users can also display information and exchange data via an NFC-compatible smartphone. Users can receive service and maintenance information, such as se-rial and order numbers or operating instructions, directly on a mobile device. LEDs indicate whether switching points have been reached and power is available. IO-Link and NFC capabilities open up a host of innovative communication possibilities and makes processes more transparent. Schmalz already uses the technology in a variety of vacuum ejectors, and the vacuum switch can be used on SPZ systems as well.

Vacuum switches and IoT

because the cost of compressed air is much higher than the cost of electricity to run a blower, making the overall system more economical and efficient. Another option is to mate a blower with a frequency converter for even higher efficiency. In essence, this variable-speed drive lets the blower produce precisely the vacuum flow needed for a given task, no more or less. This cuts power consump-

tion, and it also helps extend the life of the blower. However, such systems do carry a higher up-front cost, he cautioned.

Cups and pads Another facet in designing modular vacuum handling systems is specifying the vacuum cups themselves. They’re the critical interface between handling equipment and products. Fortunately, a wide range of push-

in or screw-in suction cups and flexible seal-ing foam are designed for many different types of products and packages. For example, vacuum cups are avail-able in various geometries including simple, circular types for general-purpose handling; extra-deep cups for round or highly curved surfaces; and oval shapes for picking up long and narrow products. They come in two general shapes, flat and bellows. Flat



P N E U M A T I C S

vacuum cups are best for handling workpieces with flat or slightly curved surfaces. Properly designed, they have good rigidity and stability to handle high shear forces and can withstand forces and accelera-tions from fast automated-handling movements. Bellows suction cups, on the other hand, have one or more accordion-like convolutions. This lets them compensate for varying workpiece heights and handle parts with uneven surfaces. Evacuating the bellows also creates a lifting action. They are often used with nonrigid packaged goods or shrink-wrapped products. The cups also come in various materials to suit a specific application and environment. Typical examples include nitrile rubber (NBR) that’s economical and is a first choice for general-purpose applications, silicone for food-grade applications, polyurethane for excellent wear resistance and high strength, and fluoroelastomers for high chemical and weathering resistance. Depending on the application, vacuum cups might need to tolerate wash-down fluids, steam or extreme cold or heat. Different vacuum cups are rated for operating temperatures from -20 to 400° F (-30 to 200° C), depending on the material. In addition to the basic version of the modular SPZ, it’s also available with supplemental mechani-cal clamping. That adds stability and holding power when handling products that are difficult to pick up using vacuum alone. Examples include PET bottles or loosely packed and partially filled cardboard boxes. Another variant combines mechanical clamping and an additional skirt that creates a vacuum suction chamber around products. It permits handling products in layers that previously could only be transported manually, such as loose cans on cardboard trays. FPW

Schmalz Inc. schmalz.com


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Hydraulics of injection molders

The

Precise metering and responsive force control are the name of the game in this specialized fluid power application. Carl Dyke • Contributing Editor

FPW_Injection Molding_5-16_Vs7 MG.MD.indd 48 5/13/16 11:14 AM

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

Plastics injection molding machines feature

a hydraulic system that must provide

reliable performance through many

years of continuous, around-the-clock

production cycling. There are a num-

ber of motion control sub-circuits for

closing the mold, for nozzle approach,

extruder screw rotation and the

injection plunge of the screw. Screw

rotation and plunge require extremely

steady motion to smoothly move the

granular plastic material through to

the heated, plasticized state and

then into the mold. These hydraulic

motions can very easily become a

quality issue for the molded product

if there is any irregularity in their

control.

There is also a need for force control sub-circuits to keep the nozzle against the sprue of the mold, and to keep the mold closed. Both of these functions are critical during the injection cycle. Mechanical force control is carried out by monitoring and adjusting hydraulic pressure.


Hydraulics of injection molders

Seals are expertly designed to keep hydraulic oil from leaking into the plastic molding process.

FPW_Injection Molding_5-16_Vs7 MG.MD.indd 49 5/13/16 11:15 AM

The cylinder that plunges the screw forward during injection and packing of the mold, together with the rotating mechanism for the screw that is turned by the hydraulic motor, makes for a complex mechanism with exacting hydraulic seal requirements. Modern seal technology has improved, allowing for leak-free hydraulic machines that are suitable even for molding plastic products for food and medical use.

Design challengesWhile some might only see a basic machine with simple hydraulic applications, the de-sign challenges faced by injection molding machine manufacturers are considerable. Molding machines are sold in an extremely competitive market, where prospects and customers are expecting accuracy, efficien-cy, reliability and ease of maintenance. The choice of main hydraulic pump is critical for providing smooth flow across the full range of working pressures, while mini-mizing input energy waste and heat build-up. While the variable volume piston pump



A complete closed-loop control scheme involves a fast processor, numerous sensor inputs and valve outputs.

has been used on some molders, moving to ever higher efficiency can be challenging—and some piston pumps require the use of a system accumulator to minimize flow pulsations. The vane pump has been a popular choice for its high volumetric efficiency and smooth flow. While some variable-volume vane pumps have been used, the fixed displacement variety of vane pumps (with its capabilities at high system pressures) performs very efficiently when coupled to a VFD motor. Many older injection molders are now commonly retrofitted with a VFD controlled pump, or a servomotor-driven pump of either the vane or internal gear design. The variable pumping rate of a VFD controlled pump is handled by varying the speed of the prime mover. When little to no motion is required during the final cooling stages of injection molding, the VFD slows the pump’s rotation to provide only the needed flow to make up for internal system leakage and maintain needed pres-sure for functions such as mold clamping.

Modern seal technology has improved, allowing for leak-free hydraulic machines that are suitable even for molding plastic products for food and medical use.

FPW_Injection Molding_5-16_Vs7 MG.MD.indd 50 5/13/16 12:02 PM

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At the very least, a pressure-compen-sated, variable-volume pump has been a useful standard for many years. The shaft of this type of pump continues to turn at full speed when no flow is required, but the displacement is minimized by reducing the size of pumping chambers (vane pump) or by minimizing piston stroke (piston pump). Again, maximum system pressure is maintained until flow demand resumes—when a directional valve opens to move a cylinder. In both scenarios above, the objective of minimizing pump displacement helps save considerably on input energy for the molding machine when little or no motion is taking place. These savings are critical for profit margins in the competitive industry of injection molding. The production of ex-cess heat is also minimized, which is impor-tant for a machine that already absorbs and radiates heat from the plasticizing heaters. When the machine is in an idle state, an unloading valve may be used to bring system pressure down to near zero by rout-ing the pump’s outlet back to tank through a relief valve with a solenoid operated unloading section connected to the relief valve’s vent pilot line.

Cylinder and hydraulic motor speeds on the injection molders of the past were largely regulated by simple needle valves. Most modern machines use electrohydrau-lic, proportional or servo valves. These zero lapped, or minimally overlapped, direc-tional valves control final actuator speeds as well as acceleration and deceleration ramps. The result is the elimination of pressure spikes and accompanying shock waves through the machine frame during decompression, or at the start and end of cylinder stroke.

Screw plunge pressure and its motion/speed are carefully controlled to aid molded product quality.

With the addition of a linear position-ing transducer on the screw plunge cylinder, and a tachometer/shaft encoder on the injector screw, very fine motion control with steady speed can be ensured for smooth, quality oriented heating and delivery of plasticized material into the mold. Naturally, all of these sensors and the variable signals needed for proportional valve inputs re-quire a fast acting programmable controller to complete a closed-loop control scheme.

Other considerationsA suitable controller should allow for prior-ity processing, and high-resolution conver-sion of the analog signals provided from the most critical sensors. In addition, the controller should feature tunable propor-tional-integral-derivative (PID) error correc-tion as a minimum standard for accurate, responsive loop control. Numerous models of controllers available today meet these needs and are designed with purpose-built, hydraulic valve drive outputs. Clamping force is an application on the molder where hydraulic pressure must be carefully maintained during the injection cycle. A pressure transducer on the hydrau-lic line to the large diameter clamp cylinder feeds a signal to the controller. During the clamp-closed portion of the cycle, the pro-portional directional valve can be controlled in a manner similar to a pressure-reducing



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

Ke y n o t e : C u t t i n g - e d g e m o b i l e h y d ra u l i c d e s i g n

Ke y n o t e : Im p o r t a n c e o f c o n t a m i n a t i o n c o n t r o l

Ke y n o t e : E f f i c i e n c i e s , t e c h a d va n c e s & s u s t a i n a b i l i t y

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

P r o p e r l y a p p l i e d e l e c t r o hyd ra u l i c c o m p o n e n t s

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

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

Carl Dyke, CD Industrial Group

Tom Wanke, MSOE

Aleksandar Egelja, Caterpillar Inc.

Expert Presenters

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

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

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

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

P r o p e r l y a p p l i e d c o o l i n g f o r h y d ra u l i c s

Tom Price, Price Engineering

FP Tech Conference 5-16_Vs4.indd 53 5/17/16 11:25 AM

5 • 2016 FLUID POWER WORLD 5554 FLUID POWER WORLD 5 • 2016 www.fluidpowerworld.com

valve, adjusting the clamp pressure to a setting that is suitable for the type of molding job being completed. In the past, a manually adjusted pressure-reducing valve was often left perma-nently set at a pressure that was too high for the clamping of some smaller molded products. Excessive pressures can stress cylinders and their seals, shortening the life cycle of components. Other cylinders, such as the nozzle approach cylinder, are often smaller in diameter and may need the higher system pressure to maintain position during the injection stage of the cycle. One application where monitored and care-fully controlled hydraulic pressure can make a difference in product quality is the plunge motion of the screw. This plunge motion is the actual injection of the plasticized material into the mold. When the initial material starts to cool as it contacts the walls of the mold, the remain-ing plastic yet to be delivered becomes harder to push, resulting in higher pressure in the


Motion and even-force control (sub-circuit pressure reduction) can be handled effectively with modern, electronically controlled, proportional or servo operated directional control valves.

Diagnostic test equipment & data logging“The Hydraulic Multimeter” with INTERPASS™ Safety Disc System Flows from 0.03 to 400 gpm, pressures to 7000 psi

Test stand instrumentationDisplay, Log, Graph & Document up to 64 inputs with ISO traceability

Flow condition monitoringFlow, Pressure, Temperature or Speed Sensors & Transducers Factory Calibrated = Fast Installation

Hydraulic componentsFlow & directional control valves, pumps and motors. Custom versions available

Toll Free: 800-932-8378 Phone: 414-769-6400 Fax: 414-769-6591 email: [email protected] website: www.webtec.com

2860 us ad3.indd 1 04/06/2014 16:51



screw plunge cylinder. This pressure, as sensed by a transducer, together with the cylinder speed, as sensed by the linear position transducer, can enable very fine proportional or servovalve control to keep pushing the screw forward, slowly, holding a suit-able pressure, or increasing pressure on a suitable curve for the already cooling plastic. This phase of injection—known as packing—is critical to ensuring the product doesn’t shrink during cooling, or warp after release from the mold. While mold designers go to great troubles to make sure that plastic can flow in an optimal way into the mold cavities, fine hydraulic flow and pres-sure control make a great contribution to the cause of product quality and optimal machine cycles. Modern electrohydraulic valves, together with sensors and programmable controllers, make up a complete process control suite. With the increased popularity of electric-motion injection molding machines, especially in the smaller size category, hydraulic component and system makers must showcase their finest, most efficient products and solutions to the manufactur-ers of the machines. Hydraulics is difficult to beat for the forces needed to mold larger products such as automobile bumpers, or for massive, multi-piece molds. Radial piston motors are still a great choice for the needed injection screw torque, and cylinders are best for smooth linear motions with high forces. With just a few updates and modifications along the way, well-built hydraulic injection molding machines are often found running reliably two and three decades after their original installation date. FPW

CD Industrial Group Inc.cdiginc.com


Discuss This



PRODUCT WORLD


Flow control valvesWebtecwebtec.com/us

The VFD family of three-port flow control valves can regulate flows

from 1.5 to 50 gpm at pressures up to 6,000 psi. The valves also offer

superb pressure compensation, ensuring the priority flow is unaffected

by variations in pressure on either of the downstream circuits. These

enhancements to the VFD line improve efficiency by 33%, making

hydraulic systems run cooler, while using less energy.

Positioning feedback cylinderCamozzi Pneumaticscamozzi-usa.com

In compliance with ISO 15552 standards, series 6PF cylinders are equipped

with a potentiometric transducer of a linear position integrated inside

the rod. This type of cylinder, when used with the LRXA4 proportional

servovalve, makes it possible to constantly control the position of the

rod along the entire stroke. The pistons of the series 6PF are equipped

with specific seals for increased accuracy and a permanent magnet to use

external end-stroke sensors. The cylinders feature bore sizes from 50 to 125

mm and stroke lengths from 50 to 500 mm (in 50-mm increments).

Friction cupsPiabpiab.com

Piab is expanding its DURAFLEX line of friction cups with three BFFT (Bellows Flat Friction Thin) cups, a design specifically developed

to provide ultimate grip on extremely thin sheets without the risk of denting the delicate surface. Sheets of thicknesses down to 0.6

to 0.8 mm can be safely handled by the new friction cups. In addition, three DCF (Deep Concave Friction) cups have also been added

to the DURAFLEX line to provide maximum hold on parts with a concave or convex surface.

FPW_Product World_5-16_Vs6.MD MG.indd 56 5/16/16 2:01 PM


Linear position sensorBalluffballuff.com

The Micropulse TA12 explosion-proof linear position sensor from Balluff is now

equipped with Generation 7 technology.

Features and benefits:

• non-contact magnetostrictive technology provides long-term

reliability

• measuring ranges up to 7,620 mm (300 in.)

• USB configuration capability for simple in-application customization

(PLUS version)

• dual-position magnet capability allows monitoring of two independent

motions (PLUS version)

• field-replaceable electronics module for fast, easy in-cylinder repairs

• standard temperature range: -40° to 80° C (-40° to 176° F)

• extended low temperature operation: -50° C (SA418 option, consult factory)

• available interfaces: analog voltage/current, Synchronous Serial Interface (SSI)

Solenoid valveFestofesto.us

The VUVS-S pneumatic valve covers up to

80% of all applications in tough and harsh

environments in automation technology.

The valve can be used with an operating

pressure of 2 to 8 bar and a flow rate of up

to 1,000 lpm. What’s more, the heavy-duty

valve is suitable for use in a temperature

range of –5 to 50° C. An extensive range

of mounting accessories provides various

options for integrating these valves into

any machine concept.

For further information about products on these pages visit the Fluid Power World website @ www.fluidpowerworld.com


PRODUCT WORLD


Piston pumpsHengli Americahengliamerica.com

HP3V series piston pumps reduce fuel consumption and

increase productivity, while providing end users excellent

reliability and long service intervals. This open circuit pump

comes in multiple sizes including: 28, 45, 60, 80, 125 and 140 cm3.

Features:

• variable pump in swash-plate design for open circuit

• continuous pressure rating of 320 bar

• self-priming capability

• optional through drive

• quick responsive controllability

• low pressure pulsation and low noise

• electronic torque control

• electronic pressure relief valve

Circuit design toolHydraForcehydraforce.com

i-Design is a manifold design software that allows users to easily create

custom integrated manifold circuits, specify valve assembly layout, and

generate a bill of material for their assembly. The user can build a circuit

using “drag and drop” technology to specify the location of valves, ports,

mounting holes and other manufacturers’ components on a manifold

surface. Version 5 supports the trends toward integrated hydraulic

systems, expanded use of electro-hydraulics, and greater global

application of hydraulic manifolds and cartridge valves. It features the

PRO add-on, a feature that can automate a manifold design and allows

for click and drag plotting of cross-drills within a hydraulic manifold.



For further information about products on these pages visit the Fluid Power World website @ www.fluidpowerworld.com

GaugesMidland Metalmidlandmetal.com

Midland metal expanded its line of gauges to include face sizes of 1½,

2 and 2½ in. They are available with 1⁄8 or ¼-in. NPT brass lower or

center back mounts. With pressure ranges from 0-15 to

0-300 psi, the gauges are suitable for measuring steam, air,

oil, water and other pressure media, which have no effect

on bronze and brass. Typical applications include:

compressors, filter regulators, water pumps,

beverage dispensing equipment, and

hydraulic and pneumatic systems.

Fitting systemVoswinkelvoswinkel.net/en

The new ECOVOS fittings with block stop feature clearly

indicate when mounting is completed. Manufactured

in nominal diameters from DN06 to DN16, the fittings

differ from their conventional counterparts with a

predefined width of the gap between the two faces

of the components to be joined. This gap prevents

excessive tightening torque, ensuring the required pre-

tension for a reliable and permanently tight connection

in the thread pairing.



AD INDEX

Aggressive Hydraulics ............... 15Anderson Metals Corp. ............. 55AutomationDirect ....................... 1CD Industrial Group .................. 17Clippard Instrument Laboratory, Inc. ....................BCEaton Hydraulics ....................... 31FABCO-AIR, Inc. ......................... 13Flaretite, Inc. ............................. 32Fluid Power Tech Conference ... 53FluiDyne Fluid Power ................ 40Gerdau Special Steel N.A. ........... 9Hercules Sealing Products ........ 25Holmbury, Inc. .......................... IBCHunger Hydraulics ..................... 33Hy-Pro Filtration ........................ 39

Hydra Mount Corporation ......... 32Kawasaki Precision Machinery .... 5Kocsis Technologies, Inc. ........... 37Main Manufacturing ................... 4Muncie Power Products .............. 3PHD Inc. ..................................... 47Price Engineering ...................... 19Prince Manufacturing Corporation .......................... 11Servo Kinetics, Inc. .................... 51Super Swivels .............................. 2Tompkins Industries .............. IFC,4Veljan Hydrair Inc. ..................... 29Webtec ...................................... 54Yates Industries ........................... 7

www.fluidpowerworld.com

LEADERSHIP TEAM

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

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

EVP Marshall [email protected]@mmatheson

May 2016

www.fluidpowerworld.com

Ag machinery relies on the versatility of hydraulics p.26 Twelve tips for better cylinder selection p.34

PAGE 42

pneumatic solution for customized machines

A Lego-like

The hydraulics of injection molders p. 48

COVER_FPW 5-16_FINAL Vs2 MG.indd 1

5/12/16 1:48 PM

Follow the whole team on twitter @FluidPowerWorld

CONNECT WITH US!

Ad Index_FPW_5-16.indd 60 5/17/16 12:50 PM

Holmbury 12-15_FPW.indd 1 5/12/16 9:57 AM

StainlessSteel Cylinders

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!

• 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

Huge Inventory. Ready to Ship Today!

Providing innovative solutions for today’s engineering challenges.

tydibility

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Clippard 5-16_FPW.indd 1 5/12/16 9:58 AM

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