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Publisher’s Note: The information provided in this publication is for informational purposes only. While all efforts have been taken to ensure the technical
material
Fluid Power Journal
not responsible for the availability, accuracy, currency, or reliability of any information, statement, opinion, or advice contained in a third party’s material. Fluid Power Journal will not be liable for any loss or damage caused by reliance on information obtained in this publication.
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Metacognition YOU CAN’T GET THERE FROM HERE
By Dan Helgerson, Technical Editor, Fluid Power Journal
» I’VE BEEN THINKING about, well, …about thinking. It turns out this is a thing, and there is a name for it: metacognition. It comes from two root words: meta, which means beyond or above, and cognition, which is “the mental action or process of acquiring knowledge and understanding through thought, experience, and the senses.” Now, this is not metaphysical, which falls within the realm of non-material things. It is simply the process of looking at ourselves to analyze our own thought patterns. It is like taking a bird’s eye view of our mind as we process information.
I live in the Northeast; in Maine, there is a story of a native Mainer being asked for the best way to get to a popular city by a visitor. The Mainer thought about the different routes that could be taken. As he thought, he remembered various construction sites, barriers, or other obstacles, and finally concluded, “You can’t get there from here.” How often do we, when faced with a challenge, revert immediately to “the way we’ve always done it,” or only look at the obstacles to trying something new?
I was at a dinner meeting with a bunch of fluid power professionals, and we were discussing the inefficiencies of fluid power systems. We recognized that our hydraulic and pneumatic systems have a power density and flexibility that exceeds most other power transfer systems, and this fact has relegated efficiency to being a side issue. In my years in fluid power, I have seen sound, pressure, flow, and power specs, but I have not seen an efficiency spec. No one has provided me with a target efficiency number to meet. At this point, one person implied that the inefficiencies are simply the cost of using fluid power. I do not remember his name, but I do remember that it frustrated me.
It is in this area of energy efficiency where we could all use a healthy dose of metacognition to think about our thinking and challenge our assumptions. We often see an attempt to make a system more efficient as being too complicated; it requires a change in our approach and thinking differently. It may be like saying, “You can’t get there from here.” But maybe we can get there if we are willing to accept a new starting point.
Metacognition is a way to challenge our deepest and most closely held ideas and assumptions, the glasses through which we see the world. What are the things we take for granted, the things we assume that go without saying? For example, most of us were taught, and so assume, that flow determines velocity. If an actuator is operating too fast, we must simply reduce the flow. And because there is a reduction in velocity when there is a corresponding reduction in flow, it seems to verify the assumption. But this wrong assumption is a major factor that has led to the report of our industry wasting nearly $80 billion annually due to the inefficiencies of our fluid power systems.
At a meeting of high-ranking executives in fluid power manufacturing, a man with a Ph.D. in fluid power made the unchallenged statement that pressure compensated piston pumps are more efficient than gear pumps. This assumption will naturally lead him to design systems using pressure-compensated pumps without considering other options that may make the system more efficient. It is likely true that most pressure compensated pumps have a greater volumetric efficiency than most gear pumps, but it may not be universally true.
In addition, the component efficiency does not equate to system efficiency. A pump that is fantastically efficient, whose flow is dumping across a relief valve, produces a system that is 100% inefficient. It may be worth ignoring our assumptions, allowing us to find a new starting point.
Words mean things, and giving new names to components or functions may help us think differently about them, opening opportunities for new starting points. Identifying a rotary/ gear flow divider as a fluid power transformer will expand our concept of its functions and provide opportunities for new applications. Renaming a flow control valve as a power limiter causes a more realistic understanding of its function in a circuit. Replacing units of force (F = p × A) with units of work (W = p × V) may help alter the way we understand the production and use of energy.
“You can’t get there from here” will be true if “here” is the way we have always done it. Think about thinking about it.
If you want to know more about the relationship between flow and velocity, drop me a line at Dan@DanHelgerson.com.
Fluid Power Journal (ISSN# 1073-7898) is the official publication of the International Fluid Power Society published monthly with four supplemental issues, including a Systems Integrator Directory, Off-Highway Suppliers Directory, Tech Directory, and Manufacturers Directory, by Innovative Designs & Publishing, Inc., 3245 Freemansburg Avenue, Palmer, PA 18045-7118. All Rights Reserved. Reproduction in whole or in part of any material in this publication is acceptable with credit. Publishers assume no liability for any information published. We reserve the right to accept or reject all advertising material and will not guarantee the return or safety of unsolicited art, photographs, or manuscripts.
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MORE THAN A MARK
WHY TRUSTING YOUR DOT FITTING MANUFACTURER MATTERS
By Ryan Stacy, Senior Director of Marketing & Product Management, Alkon Corporation
Anyone who’s worked a construction site knows uptime is non-negotiable. Every minute a dump trailer, lowboy, or equipment hauler sits idle is money lost. Within tight schedules, a single breakdown can affect an entire project. Engines, hydraulics, and tires often steal the spotlight. Yet it’s pneumatic brakes that quietly safeguard every load.
The numbers tell a sobering story. According to the Federal Motor Carrier Safety Administration (FMCSA), brake system failures contribute to nearly 30% of large truck crashes. Even more alarming, the Commercial Vehicle Safety Alliance (CVSA) reports that brake-related violations are consistently the top cause for “out of service” orders during roadside inspections. For construction trailers tasked with hauling thousands of pounds of material across uneven terrain, that risk is a daily reality.
What often goes unrecognized is the role of the smallest components in that system: fittings. These brass connectors, tucked away behind axles and under decking, are the unsung guardians of air brake reliability. A single leak, even a minor one, can bleed pressure from the system, force compressors to work overtime, and increase fuel
consumption. Worst of all, it can jeopardize stopping power when it’s needed most.
The jobsite amplifies those risks. Unlike controlled highway conditions, construction zones expose trailers to dust, vibration, extreme temperature swings, and constant jostling from uneven ground. Under those conditions, DOT-compliant, leak-free fittings are mission-critical. Components that check the right boxes on paper often fall short under real-world demands, and low-cost imports that claim DOT compliance sometimes fail safety-critical testing. Trailer safety on construction sites depends on a solid foundation built on reliable systems and components. Every part has a role in keeping projects on schedule, protecting operators, and ensuring equipment performs.
The Hidden Role of Fittings in Pneumatic Safety
When most operators think about brake maintenance, their minds go to shoes, drums, or air compressors. Rarely do they picture the small brass fittings buried deep under a trailer’s frame. These components are the lifelines that carry compressed air from tank to chamber, and a single compromised fitting
can set off a chain of failures. Even minor leaks have outsized consequences. Studies have shown that just a 10 psi drop in system pressure can increase stopping distances by more than 20%. On congested jobsites, where
dump trailers or heavy haulers must stop suddenly on loose gravel or compacted soil, that margin can mean the difference between a controlled stop and a catastrophic accident.
The risks aren’t limited to safety. According to fleet data, unscheduled roadside events cost fleets an average of $448 per incident, not including lost productivity or delayed projects. When the cost of towing a loaded trailer off an active site is added to the potential penalties tied to federal out-of-service violations, what looks like a cheap fitting can quickly become the most expensive part of the machine. Construction environments amplify those risks.
Unlike highway rigs, trailers in this sector face constant vibration, dust intrusion, and thermal cycling, all of which accelerate wear on seals and connections. These demanding conditions expose the critical differences between a properly engineered fitting and an imported lookalike. In these environments, DOT compliance becomes even more crucial. While many fittings on the market claim to meet standards, independent testing has repeatedly shown that some counterfeit or imported parts fail under leak or burst testing despite compliance markings.
For fleets and contactors, trusting these components creates risk at the point where safety margins are already the thinnest. That’s why the conversation around trailer uptime and jobsite safety cannot stop at the brake drum or compressor. It must extend all the way down to the connectors that keep air sealed tight. When the fittings hold, everything else has a fighting chance to perform.
Regulatory Compliance and Real-World Risk
Air brake systems aren’t just another maintenance checklist item; they’re regulated by some of the strictest safety standards in the transportation sector. Under 49 CFR § 571.121, the Federal Motor Vehicle Safety Standards (FMVSS) require that air brake systems maintain specific performance thresholds for stopping distance, reservoir capacity, and leak-down rates. For trailers operating in construction environments, even small deviations from compliance can trigger an out-of-service order.
While regulations set the standards, realworld enforcement shows the results. Each year, the CVSA conducts Brake Safety Week inspections across North America. In 2023, inspectors placed more than 12% of vehicles out of service for brake-related violations, with air loss from defective components ranking near the top of infractions. That downtime translates directly into emergency repairs,
liability exposure, and costly project delays. Regulations may define the standards, but they don’t guarantee that every component on the market meets them. A DOT marking on a fitting can be misleading because there is no governing body actively verifying compliance with required testing and performance standards.
Under the FMCSA, manufacturers are allowed to self-certify, meaning a DOT marking is often based solely on the company’s claim of compliance rather than independent verification. This makes it increasingly important to understand where fittings are sourced from and to rely on manufacturers that provide documented testing and proven quality. This is where component sourcing becomes a frontline safety and productivity decision. Specifying fittings from proven, U.S.-manufactured sources reduces the risk of false compliance and simplifies roadside inspections. Compliance isn’t just about avoiding fines or passing inspections. It’s about keeping crews safe, equipment moving, and delivery schedules intact. And when safety is measured in psi and stopping distance, the smallest piece carries the greatest responsibility.
The Economic Impact of Downtime and Failures
On a construction site, time is currency. When a trailer, loader, or hauler goes out of service, it doesn’t just idle equipment; it halts crews and disrupts schedules. Estimates show that unscheduled roadside events can cost fleets $448 to $760 per vehicle per day in lost productivity. Brake-related failures, particularly from substandard fittings, are frequent triggers. A single air leak can force compressors to work overtime, escalating fuel consumption and maintenance needs. When such issues result in “out-of-service” classifications, rental replacements or schedule reshuffles further inflate costs. As a result, parts that initially seemed affordable can become far more expensive than originally projected.
Consider a hypothetical case: A Midwestern contractor upgrades half its trailer fleet with low-cost imported fittings and quickly finds frequent compressor cycling and failed inspections. In one season, inefficiency and downtime cost nearly $25,000, far outweighing any initial savings. Had the trailers been equipped with domestically manufactured, DOT-compliant fittings, those disruptions may have been easily avoided. This example mirrors real-world industry trends. The principle is clear: domestic manufacturing under rigorous testing protocols delivers the operational confidence construction fleets need.
Conclusion: Building Safety from the Fittings Up
On construction sites, reliability isn’t about equipment turning on; it’s about safety systems performing under pressure. Pneumatic brakes may not draw attention, but their integrity often hinges on the smallest parts: fittings. Brake system failures remain a significant factor in heavy-vehicle accidents, present in nearly 30% of large-truck crashes. When coupled with jobsite stressors, the importance of every component becomes magnified. Choosing improperly tested or low-quality fittings might seem cost-effective. However, in real-world conditions, it’s a false economy that risks safety and drives up downtime costs. That risk is heightened by the fact that DOT markings are often based on manufacturer self-certification, making it essential to rely on suppliers with verified testing and trusted performance. Informed contractors treat fittings as investments, viewing them as insurance against disruption. In construction, where every second and every load counts, it all starts at the fitting.•
UNDERSTANDING THE BASICS OF TROUBLESHOOTING HYDRAULIC SYSTEM ELECTRICAL CONTROLS
Most electrical problems are solved by the electrician rather than the Industrial Hydraulic Technician. However, there are some basic tests that are made to determine whether the failure is related to the hydraulic system or to the electrical controls.
Solenoid operated directional control valves sometimes fail to operate. The malfunction can be caused by a seized or incompletely shifting valve spool, but it could also be caused by a failed solenoid. In fact, a seized or incompletely shifting valve spool can cause an AC solenoid failure.
The first step is to determine that the pilot valve spool (if so equipped) and main valve spool are shifting completely in their bores.
Incomplete shifting can be caused by debris as well as blocked pilot ports.
SAFETY PRECAUTION: Care must be exercised that manually shifting the valve spool does not cause the machine to activate accidentally, which could cause personal injury and machine damage.
If a solenoid has overheated, buzzes, and remains hot, it is a sign that it has an internal short, which means that the coil has an electrical leak. The coil wire insulation has broken down and the wires are touching inside the coil. A lesser possibility is that the coil has an internal ground. If the solenoid will not
operate at all, first check that it is receiving electrical power and that the interlock switch is working properly. The interlock switch prevents both solenoid coils from being energized at the same time.
If the solenoid coil is receiving electrical power but will not function, shut off and lock out the electrical power. Then disconnect both leads to the solenoid. Check the continuity of the coil with an Ohm meter on the 100 x R Ohm scale. The needle should move to near zero, meaning that the coil has a low resistance. •
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Airtight Vacuum Sealing
THE HOW & WHY
By Dane Spivak, Engineering Manager, Davasol Incorporated
The following is an opinion article written by Dane Spivak, Engineering Manager, of Davasol Incorporated. Davasol is an industrial brand management firm with numerous clients, one of which is Vacuforce LLC, with whom this article is written in partnership. The numbers provided in the examples are arbitrary and do not represent real-life data. Contact Dane Spivak by email at dspivak@davasol.com.
SEAL CONSIDERATIONS
» BEFORE FOCUSING ON vacuum sealing, it is essential to consider the fundamentals of seal implementation in fluid systems. Utilizing proper seals in any fluid system is a crucial aspect of the application, ensuring maximum performance while maintaining a safe surrounding environment. Systems can experience detrimental consequences if a leak occurs in applications such as gas lines or high-pressure hydraulics. For that reason, the sealing of such systems is highly scrutinized and often requires an experienced professional.
When it comes to relatively low-pressure air systems, obtaining the “perfect seal” becomes more of an ideal than a necessity. A few air leaks here and there may result in subtle loss of energy or local pressure, but, ultimately, compressors are sized to manage this and write it off as air consumption. Hissing and increased noise pollution are common threats from a safety perspective. An industrial compressor will typically provide over 700 kPa (100 psi) of pressure and often less at the application. Vacuum is different than pneumatic pressure, as it is lower than atmospheric pressure. Vacuum leaks can be difficult to detect; they produce little to no audible noise. Basic vacuum system air leaks rarely pose clear threats to the environment. Vacuum simply sucks in atmospheric air at low pressures; this creates more excuses for careless sealing. For a vacuum, pressure differentials are at an approximate maximum of 101 kPa (14.7 psi). Additionally, pumps and vacuum generators are often smaller, localized, and application-specific, unlike a large, centralized compressor system. These factors cause improper sealing and vacuum leaks to majorly impact the system pressure and performance. That said, a well-sealed vacuum system is important to understand and implement. Below, we will review sealing best practices, how to detect a leak, and safety measures for vacuum applications.
SEALING THREADS
There are two primary thread sealing options, as shown in Figure 1 – tapered thread interference seals and parallel thread Oring seals. In vacuum and pneumatics, the common tapered threads are NPT and BSPT(R). The male and female threads create a seal by the threads interfering and “locking” together. With tapered threads, thread sealant or thread tape is required to make a proper seal and is a must-have for installation. For many smaller threads, such as push-to-connect fittings, pre-applied thread sealant may come as standard. Larger threads and other fittings may require thread tape to be manually applied. Tapered threaded connections where thread tape/sealant is not used can cause vacuum leakage and a drop in performance.
Parallel threads, also known as straight threads, do not require thread tape. In fact, thread tape should not be used so that the O-ring can seal confidently in its intended seated position. Common straight threads are NPS or BSPP(G). O-ring seals are preferred for vacuum, as the O-ring offers a clearer sealing point with less likelihood for human error in installation compared to the tapered threads. Many vacuum manufacturers tend to use more straight threads as a result. Ideally, the male and female thread type and size should match for the right seal
and connection. For example, if you have a 1/4NPT female thread, a 1/4NPT male thread should be used, with thread sealant, of course. However, straight female threads can accept tapered male threads while still offering an appropriate seal. Additionally, male threaded universal O-ring seals can fit and seal on NPT, NPS, BSPT, and BSPP threads, which include female tapered threads. Figure 2 demonstrates a tapered male thread and universal thread sealing in the aforementioned scenarios.
TUBING & HOSE SEALS
When using tubing OD sizes of 1/2" or less, vacuum is much like pneumatics, where pushto-connect fittings are the preferred means of connection. Standard pneumatic tubing, such as PU, PE, and nylon materials, are also used. Other connection parts, such as stems, nipples, or compression fittings, are also used but are much less common. It goes without saying that a quality, well-sealed push fitting is the best practical use. However, the internal O-ring design and tolerance ultimately decide the quality of a vacuum seal. Refer to Figure 3, which shows a cutaway of two fittings with an internal O-ring and irregularly shaped seal. With push-to-connect fittings, the outer diameter of the tubing seals against the internal
Fig 1 Tapered and parallel threaded connections
Fig 2 Tapered and universal male threads sealing in different female thread types
rubber seal of the fitting. Under vacuum, the tubing can slightly collapse, which may cause air to leak under the traditional round O-ring seal. However, the pronounced irregularly shaped style seal can move with the collapsed tubing and maintain a seal under these same conditions. For that reason, it is important to use vacuum rated push fittings along with the exact matching tube to push fitting size.
Vacuum hose sizes above 1/2", where push fittings can no longer be used, are straightforward. Other than ensuring the hose itself is vacuum rated, which usually has a coil reinforcement to prevent collapse, the hose simply needs to be pushed onto a barb and securely clamped down on its OD. Under vacuum, the pressure will only help the hose collapse down and seal against the barb. Figure 4 demonstrates this connection and seal.
DETECTING LEAKS
There are different techniques to detect vacuum leaks, including the following two simple strategies for relatively smaller use applications. A regular occurrence for new vacuum systems or component installations is to seemingly have everything set up correctly, but not achieve a high or maximum vacuum level. Often, there are one or more vacuum leaks in the system, and as previously discussed in this article, they can be difficult to find. The first step would be to review all possible leak points and ensure all components, connections, and seals are vacuum appropriate. The first and most important part of the test is to turn on the vacuum. If possible, continue to run the application as intended, if feasible. The vacuum pressures and flows
must be applied as components can move and operate differently under these conditions. Blasting compressed air through the system may uncover weak spots but expose leaks that would possibly damage system components and otherwise not exist under vacuum. This practice is not recommended. A vacuum leak detector works by identifying leaks in a sealed system that is under low-pressure vacuum. It typically uses a sensor to detect the presence of gases escaping into the vacuum, which indicates a leak. Common detection methods include the use of helium, introduced around the suspected leak area. From there, a mass spectrometer detects any helium that enters the system. It can also detect pressure decay, where the system is sealed and monitored, for a drop in pressure over time. These detectors help ensure system integrity in applications like aerospace, manufacturing, and scientific equipment. Other rudimentary style approaches can be used to detect leaks, such as using water, non-toxic smoke, or stethoscope tests directed at potential leak points.
SAFETY AROUND LEAKS
Working around vacuum systems for air use only is generally considered safe for humans. Vacuum flow from applications or leaks is harmless overall. It is not unheard of to check for flow or vacuum suction force by putting your hand near or on an applicable vacuum area. However, this is not considered safe nor recommended. Vacuum can cause damage, and human skin is an excellent sealing material that can allow for high vacuum levels and forces. Industrial pumps can produce much higher pressures than a shop vac or vacuum carpet cleaner. Around a vacuum, it is best to avoid contact or sealing against your body.
CONCLUSION
As reviewed in this article, sealing techniques under vacuum conditions can differ from other applications. The pressure lower than atmospheric creates a unique approach to using the correct components and sealing strategies. Due to its relatively harmless nature, vacuum seals are not regarded as a top priority despite their high potential to influence performance. While vacuum is considered safer than most other fluid power applications, correct testing and safety measures should be employed.
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It’s our turn.
Fig 3 Round O-ring (left) and flanged seal (right)
Over 31 years, I have progressed from a young engineer at Heavy Engineering Corporation (HEC), India, to leading projects, maintenance, and plant engineering across Asia, Europe, and the U.S. My experience spans heavy engineering, steel, mining, oil and gas, marine, aerospace, and defense. Working with top consultants, I have helped develop initial scopes for many large, impactful projects.
I routinely witnessed the difficulties in allocating resources and securing investment for upgrading fluid power systems or converting inefficient mechanical systems into hydraulically operated ones. Why have plants with innovative facilities, equipped with the latest PLCs, HMIs, and robotics, relied on decades-old fluid power systems with the most primitive designs? I wish there had been resources available to me during my early years that could have helped me navigate the difficult terrain of presenting the viability and cost-effectiveness of my project.
So, here it is, a guide to providing engineers with a pathway to secure systems investment by presenting strong cases, thereby reaping the benefits of a business operating with upgraded fluid power systems.
Quest to Prove Worthiness
Investments in a business must drive measurable value, making it critical that any proposal clearly demonstrates how it maximizes the internal rate of return and improves business outcomes. Although front-end asset upgrades often receive attention due to their visible impact, back-end assets like fluid power and utility systems support ongoing production
and business performance around the clock. Overlooking these systems can result in unnoticed risks until a failure disrupts operations, delaying order fulfillment and threatening business objectives. Presenting a direct connection between the reliability of these systems and the company's key performance indicators strengthens the investment case.
Corrective and Preventive Action (CAPA) reviews frequently show that investment in control and automation integration for frontend assets is prioritized, while original fluid power systems are neglected. Their ongoing operation can mask risks to throughput, efficiency, and profitability, making upgrades appear less urgent. Clarifying the operational and financial impact of fluid power system performance, such as effects on product quality, throughput, and maintenance costs, makes it easier to articulate a business case encompassing all relevant benefits and aligning directly with broader company goals.
Wide-Angle View Illustrating Potential Benefits
How can we evaluate and project the need to modernize fluid power systems and connected assets emphatically? A broader perspective is essential while making a case. One must consider tapping into all the potential opportunities that can impact both the top and the bottom lines of the business. To do justice to the business’s hard-earned dollars and keep the company’s competitiveness intact for many years, a thorough understanding of the gap in the present status of the assets and all potential benefits through upgrade is essential.
In-depth knowledge about solutions is increasingly expected from technical managers to upgrade and accomplish world-class operations. This is only possible by constantly keeping up with newer technology and connecting with academicians, manufacturers, researchers, and presenters at Industry conferences and seminars. Systematic approaches help in justifying the investment from a broader perspective.
Relying on Safety First
Many legacy fluid power systems lack operational and maintenance safety based on today’s standards. They often fail to offer protection of system components through proper interlocks. In special circumstances outside of normal operation, a system can pose a risk to personnel or to equipment. For example, a project that addresses a fluid power system without proper safety interlocks, or a sequence of operation in a process that doesn’t offer enough safeguards against human error, is easily justifiable. The presence of unsafe conditions supersedes monetary considerations and is considered a priority by management, as it poses a high degree of risk to the business. Hence, the first and foremost expectation from a fluid power engineer is to identify such risks and address risk abatement via an upgrade plan. Highlighting safety risk resolution guarantees that the project will make it to the top tier for consideration.
Leveraging Overall Equipment Effectiveness
The normal function of a fluid power system is seen as binary, with the system
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running or under breakdown. However, an overall equipment effectiveness (OEE) perspective is more appropriate while considering business impact. OEE is a function of availability, performance, and quality; it provides a comprehensive measure to determine if the equipment is working per its designed efficiency level. A frequent reliability issue with system components results in lowering plant availability. Internal leaks, slippage, and low efficiency operations due to worn parts affect the system adversely. The impact can be categorized as lower performance in terms of extended cycle times that lessen productivity. A loss in designed operating parameters, such as pressure, flow, and control issues, yields poor quality products. Consider the following two breakdowns:
OEE = availability × performance × quality, with 90% availability, 90% performance, and 90% quality = very low OEE even at 90%.
OEE = 0.9 × 0.9 × 0.9 = 0.729%, far below the world-class OEE of 85%.
Any investment that helps improve fluid power systems and raises a small percentage of availability, quality, and performance can drive OEE to a much higher percentage, easily justifying the Investment with excellent payback.
Migration to a Cost-Effective and Reduced Labor Maintenance Regimen
Normally, the age of legacy fluid power systems ranges between 20 and 30 years or more, with minimal feedback and diagnostic capabilities. This provides a low-hanging opportunity to augment the system with the latest feedback and features. A system equipped with PDM sensors can help in eliminating the dependency on manual inspection with real-time feedback and corrective action recommendations. The approach is a game-changer, transforming reactive maintenance to be proactive and impactful to uptime and OEE.
Investment in a well-designed and informative human machine interface (HMI) equipped with real-time notifications and trending capability can help clarify the entire process and boost both efficiency and uptime. The upgraded system can seamlessly synchronize with a modern computer-managed maintenance system (CMMS), further enhancing asset reliability with the latest predictive management tools. For instance, CMMS systems like Fluke EMaint. can import the data and autogenerate preventive work
orders, minimizing maintenance workforce time spent inspecting and gathering data. This time can be better utilized for more productive work. It is the responsibility of fluid power engineers to secure investment through comprehensive upgrade planning, including the projection of all the tangible and intangible benefits for business profitability with accelerated payback.
Highlighting Positive Impact on Business
Being technocrats, we are very detail-oriented and tech-heavy when it comes to presenting our project benefits. However, using complex jargon and highlighting benefits only at the system level may not be effective in impressing project sponsors. It is very important to lay out how the business will benefit from the investment. Do the benefits of the upgrade help in increasing top-line gross revenue, or make a significant impact on the net income and profit bottom line? Does the upgrade bring the organization any competitive edge that is unique to the sector or Industry? Presenting the impact of an upgrade with more direct and obvious benefits helps to connect the dots, leading to a favorable consideration of the upgrade proposal.
Conclusion
Industry 5.0 is all about connected assets, real-time data collection, and AI-driven data analytics to redefine the years-old manufacturing processes. Technology is changing faster than ever before, offering a broad spectrum of tools that impact every area of manufacturing. The innovations and techdriven solutions provide an opportunity to bring fluid power system reliability and efficiency to the next level, redefining the processes they cater to. However, it is easy to be left behind if fluid power engineers are not connected with evolving technology. It’s also possible to miss opportunities due to the lack of understanding of our systems' impact on the connected process, and consequent business profitability. It is exciting to see the way fluid power systems have evolved in the last few decades, encompassing the latest technologies and making it possible to operate at peak levels of safety and reliability. As subject matter experts (SMEs), fluid power engineers must be prudent in tapping the benefits by upgrading systems in a timely manner.•
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SMART HYDRAULICS FLUID MARKET POISED FOR GROUNDBREAKING EXPANSION
By Neha Patil, Fairfield Market Research
In recent years, the industrial and manufacturing sectors have undergone a significant transformation due to technological advancements. Among the most impactful of these developments is the rise of smart technologies. One area that is particularly benefiting from this innovation is the hydraulics industry. The smart hydraulics fluid market is on the verge of groundbreaking expansion, integrating advanced monitoring systems, automation, and fluid optimization strategies, reshaping how hydraulic systems function across various industries.
Fairfield Market Research illustrates that the Smart Hydraulics Fluid Market is experiencing significant growth, expected to rise from $4.2 billion USD in 2022 to $6.3 billion USD by 2030, with a robust CAGR of 5.9% from 2023 to 2030. The surge in demand is driven by increasing industrial automation, advancements in sensor technology, and a shift toward eco-friendly solutions.
BREAKING IT DOWN
Smart hydraulic fluids are specially designed for hydraulic systems that incorporate sensors, connectivity, and data analytics to optimize performance and provide real-time monitoring. These fluids are not just traditional
hydraulic oils; they are embedded with technologies that enable them to detect changes in pressure, temperature, and viscosity, and adjust their properties accordingly. This dynamic behavior ensures that the hydraulic system remains efficient, safe, and sustainable under various operating conditions.
Incorporating smart characteristics into hydraulic fluids offers a variety of benefits, such as improving system efficiency, reducing maintenance costs, enhancing energy savings, and prolonging the lifespan of hydraulic equipment. The global demand for these high-performance fluids is growing rapidly, driven by the continuous need for industrial automation, energy-efficient machinery, and sustainable practices.
THE APPLICATION OF SMART TECHNOLOGIES IN HYDRAULICS
Historically, hydraulic systems were mainly monitored and maintained manually, relying on human operators to detect issues like fluid contamination, leaks, or irregularities in the system’s pressure or temperature. However, the landscape of hydraulic systems has changed drastically with the advent of smart technologies such as the Industrial Internet of Things (IIoT), sensors, and AI-driven analytics.
The introduction of IoT-enabled sensors in hydraulic fluid formulations means that manufacturers can now collect real-time data detailing the fluid’s condition, including viscosity levels, temperature changes, and potential system malfunctions. These sensors communicate directly with control systems, providing feedback to operators about necessary maintenance actions before they become costly repairs. Additionally, these systems allow for predictive maintenance, where data collected over time is analyzed to anticipate failures before they occur.
Smart hydraulic fluids can adjust to changes in operational conditions, such as fluctuations in pressure and temperature, without human intervention. This results in smoother operation and significantly reduces the likelihood of system downtime or unexpected failures. With advancements in sensor technology, artificial intelligence, and data analytics, the ability to optimize and manage hydraulic systems in real-time is now a reality. This transformation is expected to further accelerate as industries continue to adopt smart technologies to remain competitive.
Several key factors drive the expansion of the smart hydraulics fluid market. These include the increasing demand for industrial automation, energy efficiency, and sustainability. Let’s explore these drivers in greater detail.
GROWING INDUSTRIAL AUTOMATION
The rise of automation across various industries such as manufacturing, construction, automotive, and agriculture is a major factor fueling the demand for smart hydraulic fluids. Automated systems rely on hydraulic power to perform a wide range of tasks, from lifting and moving materials to powering large machinery. As automation becomes more prevalent, the need for high-performance, smart hydraulic fluids is also growing.
Smart hydraulic fluids offer automation systems more precision, reliability, and durability. With the ability to monitor and adjust performance in real-time, these fluids help ensure that automated systems operate with minimal human intervention, maximizing productivity while minimizing downtime.
ENERGY EFFICIENCY
In today’s competitive industrial landscape, energy efficiency is more important than ever. As industries strive to reduce their carbon footprint and lower operational costs, smart hydraulic fluids offer a valuable solution. These fluids are engineered to maintain optimal viscosity, which helps reduce friction and energy consumption within hydraulic systems.
By minimizing energy loss, companies can significantly cut down on their energy usage, resulting in both cost savings and a greener operation. The rise in the adoption of energy-efficient hydraulic systems is expected to push the smart hydraulics fluid market toward greater expansion. As more industries adopt green technologies and commit to sustainability, the demand for smart hydraulic fluids is set to rise.
PREDICTIVE MAINTENANCE AND REDUCED DOWNTIME
One of the biggest challenges in industries that rely on hydraulic systems is unplanned downtime due to system failures. In traditional hydraulic systems, breakdowns are often not detected until they result in significant damage. However, with smart hydraulic fluids, the incorporation of sensors allows for predictive maintenance, which can detect issues early and reduce the likelihood of a catastrophic failure. Predictive maintenance improves the reliability and longevity of equipment, reduces maintenance costs, and boosts operational efficiency. As the importance of minimizing downtime becomes more apparent, the demand for smart hydraulic fluids equipped with advanced monitoring capabilities will continue to grow.
SUSTAINABILITY AND ECO-FRIENDLY SOLUTIONS
As the global push for sustainability intensifies, industries are looking for ways to reduce their environmental impact. Traditional hydraulic fluids can be harmful to the environment if they leak or spill, but smart hydraulic fluids are being developed with eco-friendly properties that make them safer for both workers and the environment. Moreover, smart fluids can help optimize the use of resources, reduce waste, and extend the lifespan of equipment, which aligns perfectly with the growing trend of sustainability across industries.
KEY PLAYERS
The smart hydraulics fluid market is highly competitive, with several key players leading the charge in developing and delivering advanced hydraulic fluid solutions. These companies are investing heavily in R&D to create next-generation fluids that incorporate smart technologies such as sensors, real-time data analytics, and advanced fluid formulations. Additionally, startups and smaller companies specializing in advanced fluid technologies are making their mark in this space by offering more specialized, niche solutions that meet the demands of specific industries.
THE FUTURE OF SMART HYDRAULICS FLUID MARKET
The future of the Smart Hydraulics Fluid Market is optimistic. In the coming years, smart hydraulic fluids will likely become a standard feature in hydraulic systems across various industries. These fluids will play a key role in improving efficiency, reducing environmental impact, and ensuring the longevity of machinery.
Moreover, the market is likely to see an increased focus on biodegradable and environmentally friendly smart hydraulic fluids, driven by the growing emphasis on sustainability. With more industries transitioning to smart solutions and embracing green technologies, the smart hydraulics fluid market is on track for groundbreaking expansion.•
Newly Certified Professionals
JULY 2025
E
Jonathan Schmidt, Neff Press Inc.
ECS
Thomas Bon, North Dakota State University
HS
Byron Payne, Applied Fluid Power
Brent Deweerdt, Supreme Integrated Technology
Caleb Acquah, Hercules Sealing
David Dodt, Hercules Sealing Products
Dylan Colt, SunSource
Ethan Pickett, Motion Industries, Inc.
Harshraj Zala
Jerry Toler, Livingston & Haven
Matthew Chrysler, Custom Truck One Source
Thomas Yarick, Parker
IHM
Jacob Hayden, The Boeing Company
Jonathan Perdun, The Boeing Company
Ross Jackman, The Boeing Company
MHM
Adam Tucker, Alabama Power
Adrien Frank, Altec Industries, Inc.
Andrew Gerold, Altec Industries, Inc.
Anthony Arnold, Ameren
Anthony Ginn, Altec Industries, Inc.
Benjamin Lucas, AEP
Briar Armstrong, AEP
Brody Watt, AEP
Carlton Dougherty, Altec Industries, Inc.
Christopher Johnson, Alabama Power
David Jones, Ameren
Derek Lucas, AEP
Donnie Shook, Terex
Eric Sparr, Ameren
Forrest Logan, AEP
Jake Kiper, Altec Industries, Inc.
James Hutt-Borreslli, Altec Industries, Inc.
Jason Horn, Ameren
Jeremy Moore, Altec Industries, Inc.
John Sengson, Altec Industries, Inc.
Joseph Wells, Ameren
Joshua Traywick, Alabama Power
Justin Ritchie, Altec Industries, Inc.
Kenneth Russell, Alabama Power
Levi Miltimore, AEP
Matthew Knight, Duquesne Light
Matthew Schultz, AEP
Michael Bond, Altec Industries, Inc.
Michael Marquez Arias, Altec Industries, Inc.
Mike Raines, Altec Industries, Inc.
Nathan Green, Altec Industries, Inc.
Oscar Rodriguez, SCE
Paul Henry, Ameren
Robert Goodman, Altec Industries, Inc.
Terrence Wilke, Terex Utilities
Thomas Durant, Altec Industries, Inc.
Timothy Rindorf, Altec Industries, Inc.
Todd Vemmer, Ameren
Trey Whittaker, Altec Industries, Inc.
Tyler Best, Altec Industries, Inc.
Yamfrank Prazuela, Altec Industries, Inc.
PS
S
Derek
Thomas Yarick, Parker
SA
Benjamin Hooper, One Hydraulics
Connor Borwege, MJ Hydrostatics
Derek Randklev, IFP Motion Solutions Inc.
Randklev, IFP Motion Solutions Inc.
Support the Growth of the Fluid Power Industry Through IFPS Sponsorship
» THE INTERNATIONAL FLUID Power Society (IFPS) offers a sponsorship program that allows companies to play an active role in advancing the future of the industry. By becoming a sponsor, organizations demonstrate their commitment to supporting education, certification, and training programs that strengthen the workforce and prepare professionals for the challenges ahead.
Sponsorship is more than a recognition opportunity. It connects companies with a wide audience of professionals, educators, and students, providing valuable visibility while showcasing a dedication to industry progress. Sponsors help IFPS expand resources that keep knowledge current, promote safety, and encourage the next generation of fluid power talent to build meaningful careers.
Every sponsorship directly contributes to the Society’s mission of promoting professionalism and growth across the fluid power community. Companies that support IFPS are investing not only in the future of their own organizations, but in the long-term success of the entire industry.
Email info@ifps.org Learn more about how your company can become an IFPS sponsor.
Exclusive Access to the IFPS Educational and Training Video Library
» THE IFPS SUPPORTS its members with valuable resources that make ongoing learning simple and accessible. One of the most popular benefits is the educational and training video library, which offers a wide range of content designed to strengthen knowledge in hydraulics, pneumatics, controls, safety, and related technologies.
This growing collection is available exclusively to IFPS members, giving them unlimited access to high-quality instructional videos created by industry experts. The library is an excellent tool for individuals who want to build their skills, refresh their understanding of core concepts, or prepare for IFPS certification exams. It also serves as a reliable resource for employers who want to provide consistent, cost-effective training materials to their teams.
The IFPS video library is continually updated to reflect new technologies and best practices, ensuring that members have access to current information that supports both career growth and organizational success. Whether you are a technician seeking practical tips, an engineer working on advanced applications, or a manager looking for training tools for your staff, this member benefit provides a convenient way to stay informed and competitive. Gain full access to the IFPS training video library by becoming a member today at www.ifps.org.
Advancing Skills Through IFPS Technical Training Programs
» HOW CAN TODAY’S fluid power professionals stay sharp in a rapidly changing industry? One of the most effective ways is through structured continuous training. The International Fluid Power Society (IFPS) is dedicated to advancing knowledge and skill within the fluid power industry, and its technical training programs are an essential part of that mission. These programs
provide professionals with practical, industry-focused education that combines core principles with hands-on applications, helping participants strengthen their expertise in hydraulics, pneumatics, and system controls.
Training is designed not only to prepare individuals for IFPS certification exams, but also to improve day-to-day performance in the workplace. By building a stronger understanding of fluid power systems, participants are better equipped to troubleshoot issues, reduce downtime, and work more efficiently. This makes IFPS technical training valuable for individuals seeking to advance their careers and for companies aiming to enhance the skills and productivity of their teams.
With flexible options that include in-person workshops and online learning, IFPS makes technical training accessible to employees at every stage of their careers. Many employers use these programs as a foundation for workforce development, ensuring their teams have the tools and knowledge to succeed in increasingly complex industrial environments.
By investing in technical training, companies can build stronger teams, improve safety, and increase productivity, while individuals gain the confidence and practical expertise to excel in their roles. Learn more about IFPS technical training opportunities at www.ifps.org.
Individuals wishing to take any IFPS written certification tests can select from convenient locations across the United States and Canada. IFPS is able to offer these locations through its affiliation with the Consortium of College Testing Centers provided by National College Testing Association. Contact Kyle Pollander at Kpollander@ifps.org if you do not see a location near you. Every effort will be made to accommodate your needs.
Written Certification Test Locations
Alabama Auburn, AL Birmingham, AL Calera, AL Decatur, AL Huntsville, AL Jacksonville, AL Mobile, AL Montgomery, AL Normal, AL Tuscaloosa, AL
Alaska Anchorage, AK Fairbanks, AK
Arizona Flagstaff, AZ Glendale, AZ Mesa, AZ Phoenix, AZ Prescott, AZ Scottsdale, AZ
Sierra Vista, AZ Tempe, AZ Thatcher, AZ Tucson, AZ Yuma, AZ
Arkansas Bentonville, AR Hot Springs, AR Little Rock, AR
TENTATIVE TESTING DATES FOR ALL LOCATIONS
NOVEMBER 2025
Tuesday 11/4 • Thursday 11/20
DECEMBER 2025
Tuesday 12/9 • Thursday 12/18
JANUARY 2026
TBD • TBD
FEBRUARY 2026
TBD • TBD
JOB PERFORMANCE TEST LOCATIONS
Arizona California Colorado Florida Georgia
Maine Michigan Minnesota Montana New Jersey Nova Scotia Pennsylvania Texas Washington Wyoming Western Australia
California Aptos, CA Arcata, CA Bakersfield, CA Dixon, CA Encinitas, CA Fresno, CA Irvine, CA
Marysville, CA Riverside, CA Salinas, CA San Diego, CA San Jose, CA
San Luis Obispo, CA Santa Ana, CA Santa Maria, CA Santa Rosa, CA Tustin, CA Yucaipa, CA
Colorado Aurora, CO Boulder, CO Springs, CO Denver, CO Durango, CO Ft. Collins, CO Greeley, CO Lakewood, CO Littleton, CO Pueblo, CO
Master of Mobile Hydraulics (Must Obtain CFPMHM, CFPMHT, & CFPCC)
CFPMIP
Certified Fluid Power
Master of Industrial Pneumatics (Must Obtain CFPPM, CFPPT, & CFPCC)
CFPCC
Certified Fluid Power
Connector & Conductor
CFPSD
Fluid Power System Designer
CFPSA
Certified Fluid Power Support Associate
Tentative Certification Review Training
IFPS offers onsite review training for small groups of at least 10 persons. An IFPS accredited instructor visits your company to conduct the review. Contact kpollander@ifps.org for details of the scheduled onsite reviews listed below.
FLUID POWER SUPPORT ASSOCIATE
» CFC Industrial Training – Fairfield, Ohio | December 1–4, 2025
HYDRAULIC SPECIALIST
For custom IFPS training inquiries, please contact Bj Wagner (bwagner@ifps.org)
ELECTRONIC CONTROLS SPECIALIST
For custom IFPS training inquiries, please contact Bj Wagner (bwagner@ifps.org).
PNEUMATIC SPECIALIST
For custom IFPS training inquiries, please contact Bj Wagner (bwagner@ifps.org)
CONNECTOR & CONDUCTOR
For custom IFPS training inquiries, please contact Bj Wagner (bwagner@ifps.org).
MOBILE HYDRAULIC MECHANIC
For custom training IFPS inquiries, please contact Bj Wagner (bwagner@ifps.org)
Online Mobile Hydraulic Mechanic certification review for written test is offered through CFC Industrial Training. This course surveys the MHM Study Manual (6.5 hours) and every outcome to prepare you for the written test. Members may e-mail for a 20% coupon code off the list price. Test fees are not included.
INDUSTRIAL HYDRAULIC MECHANIC
For custom IFPS training inquiries, please contact Bj Wagner (bwagner@ifps.org).
INDUSTRIAL HYDRAULIC TECHNICIAN
For custom IFPS training inquiries, please contact Bj Wagner (bwagner@ifps.org).
» For dates, call CFC Industrial Training at (513) 874-3225 or visit www.cfcindustrialtraining.com.
MOBILE HYDRAULIC TECHNICIAN
For custom IFPS training inquiries, please contact Bj Wagner (bwagner@ifps.org).
PNEUMATIC TECHNICIAN & PNEUMATIC MECHANIC
For custom IFPS training inquiries, please contact Bj Wagner (bwagner@ifps.org).
» For dates, call CFC Industrial Training at (513) 874-3225 or visit www.cfcindustrialtraining.com.
Lubriplate’s complete line of ultra high-performance, hydraulic fluids has been designed to provide a wide range of benefits including: extended fluid change intervals, cooler operating temperatures, reduced friction and reduced downtime. Products include...
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The Tangible Benefits ofZero-Leak
RotaryValvesShear
By Martin Cuthbert, Managing Director, Webtec
Real-World Application of Zero-Leak Rotary Shear Valves
When it comes to maintaining safety-critical machinery, not all are aware of the benefits provided by zero-leak rotary shear directional control valves with Pressure Decay Proof (PDP®) technology. Webtec has helped many hydraulic machinery OEMs and operators overcome challenges using these innovative and versatile valves, achieving exceptional results.. To highlight the tangible gains and added value available from zero-leak rotary shear valves, consider a real-world application at a company supplying oil well safety equipment and mobile drilling rigs. Although the company had been in business for many years, it was finding it harder to make a profit due to an aging fleet of machinery and subsequent reliability issues. Sourcing spare parts was also becoming increasingly difficult.
To help combat technical issues like these, the company relies on the expertise of its team. However, in this project, the design engineer and service manager had vastly different challenges.
The design engineer was tasked with designing a new, simplified valve that would also provide better control of oil well safety equipment. The service manager needed a replacement valve to control winches on mobile drilling rigs, with the aim of keeping machines running for longer without incurring additional costs. With both professionals requiring a hydraulic valve solution, they sought Webtec’s expertise and its Make it BLUE (Begin, Listen, Upgrade, Engineer) approach to custom products. In both cases, outcomes proved highly successful.
Four Key Challenges
Fig.1
The design engineer condensed the task of simplifying the oil well safety equipment circuit into key challenges, inclusive of reducing from two valves to one and minimizing the piping requirements. Other processes included introducing high-pressure capability and improving safety through a tamperproof valve design. The engineer preferred an accumulator-fed safety system with a blow-out preventer. A key requirement was avoiding leakage from the accumulator when the cylinder is idle to guarantee the availability of power in an emergency. Typically, this type of design employs a shut-off/isolating valve
to hold pressure inside the accumulator and a second valve to control flow direction.
Reducing to a single valve meant devising a more innovative solution than using a conventional 3-position, 4-port sliding spool valve, which tends to leak in the closed position due to the 5-10 µm gap that exists between the outer diameter of the spool and inner diameter of the honed bore. This gap may lead to leakage of around 0.5 to 1.0 l/min at the valve’s rated pressure. While not critical in many hydraulic applications, this leakage rate is unacceptable in safety-critical systems. Moreover, leaks bring particulates through the valve, some of which can get stuck and cause accumulation that prevents valve actuation.
A rotary shear valve has a different design featuring pressure-loaded seats and a rotor.
Rotary Shear Directional Control Valve
Fig. 2 Leakproof arrangement with sliding spool directional valve and isolating valve
These hardened and lapped components have optically flat mirror finishes to provide metalto-metal contact with zero or near-zero leakage depending on flow. In this design, the higher the pressure, the more the surfaces get pushed together. With only one valve needed for both zero leak and directional control, the design engineer could dispense with the isolating valve, saving space, inventory, and costs.
Pipe Dreams Come True
Simplifying the oil well safety system also meant specifying a bespoke valve that would help minimize piping requirements and reduce installation costs. Ultimately, preference was expressed for a custom 8-port valve with 4 ports duplicated on the bottom and side. This configuration would provide the advantage of choosing which ports to use in various instances, while simply plugging the remainder.
Under Pressure
Although requests for shear valves with high-pressure capability are not unusual, a unique aspect of this project was the desire of design engineer to place multiple shear valves in series. The engineer specified a 35 MPa (5,000 psi) valve to pressurize the tank line and feed that flow into the pressure line of the next valve in series. Options included pressurizing the T port and manufacturing a much stronger valve, or introducing a fifth port with a case drain from the top cap that feeds to the tank separately. While both were feasible, the design engineer selected the latter.
Safe, Not Sorry
To ensure tamperproof operation of the valve, the design engineer sought a lockable option. Choices here included a button lock or a key lock. The chosen button lock mechanism features a unique locking plunger. After
moving the valve handle, the plunger autolocks the handle into position. The operator must pull the plunger release manually to disengage from the lock position.
Applying a Four-Step Process
By designing a custom zero-leak rotary shear valve solution in line with the four-step Make it BLUE process, the design engineer overcame key challenges. The same would prove true for the service manager designing a replacement for controlling winches on ageing mobile drilling rigs with a few extra features. Like the design engineer, the service manager also identified the need to combine directional and pressure control, introduce flow regulation, implement remote mechanical actuation, and withstand exposure to salt and humidity. With the existing valve featuring built-in relief, the service manager wanted a replacement with combined directional and pressure control capabilities. Using a spool valve was not the answer because leakage in the closed position would cause the winch load to creep downwards when it should remain stationary. The answer was the adoption of a zero-leak rotary shear valve, making it possible to direct flow to the cylinders, remove the brake, and allow the winch to operate. In this circuit, there was also a secondary function where an override valve would still permit winch movement in the event of power failure.
In addition, the service manager needed an integral pilot relief valve with a pressurized tank port and an additional vent/tank connection. The incoming pressure line would therefore benefit from protection by the relief valve. The solution also took advantage of a vented tank connection fifth port.
Interflow Requirement
Another requirement was finer flow regulation/control for the operator without installing
a separate flow regulation valve. Achieving flow regulation with a directional control valve necessitates an interflow design that prompts a small amount of flow while the valve transitions from one position to the next. The result is more controlled cylinder performance, which is essential to winch work.
Mechanical Actuation
The valve needed remote mechanical actuation via a unique linkage, as it was located deep inside the machine. Mechanical actuation options included a detent design where the handle stays put after actuation, or spring centering, in which the handle returns to its original position. In this case, the handle was removed and replaced with a pin to connect the mechanical actuator.
Weatherproofing
As a mobile drilling rig, the machine endures exposure to a variety of environments, including coastal, hence the requirement for a zero-leak rotary shear valve with a stainless-steel body. Webtec, serving as an expert in the design and manufacture of these valve types, has helped many hydraulic machinery OEMs and operators overcome the aforementioned challenges using these innovative and versatile valves, achieving exceptional results in the process.
Conclusion
By combining zero-leak performance, durability, and customization through Webtec’s Make it BLUE process, rotary shear valves prove to be a powerful solution that helps engineers and operators alike achieve safer, more efficient, and more cost-effective hydraulic systems. •
Fig. 5 Valve locking options
Fig. 6 Winch lowering during power failure
Fig. 3 Rotary shear valve principle of operation
Fig. 4 Leakproof arrangement with rotary shear directional valve
Fig. 7 Flow regulation using interflow design
Fig. 8 Remote mechanical operation
PRODUCT SPOTLIGHT
APVS Media Separated Valve Series Provides Safe Operations for Handling Caustic Media
The APVS Series distinguishes itself from others by allowing high-flow with minimal path restrictions and an extensive seal selection for media compatibility. includes inert gas/ spring-operated valves to control high-purity, aggressive, and corrosive liquid chemicals while allowing a flow rate superior to other similar valves on the market. Available with an optional magnetic position sensor to maintain positive feedback. Learn more about our products at www.spartanscientific.com.
At Continental Hydraulics / Hydreco, we manufacture high-quality HPUs, pumps, motors, valves, and manifolds with short leadtime. Don’t take the risk of using substandard solutions when these products have a strong influence on machine efficiency, productivity and operating expenses. Rely on us, a premier fluid power manufacturer, and benefit from our expertise and world-leading variable frequency drive technology. continentalhydraulics.com sales@conthyd.com
ES Series Electronic Valves
The ES 2-Way and 3-Way valves feature ultra-low leak rates, fast response, multiple flow rates and cycle life of over 1 billion. Clippard’s proven spider technology utilizes one moving part enabling the ES to operate with exceptional reliability
The compact footprint coupled with the long life, and exceptional leak resistance make the ES line suited to improve reliability in a wide range of applications including biomedical, dental, test equipment, oxygen control, textile, packaging, pressure control, automation and portable systems.
PRODUCT SPOTLIGHT
Coxreels® TDMP Dual Hydraulic Reel!
TDPM reel is robustly built for capacities up to 50’, with triple axel support, dual arm guides, and stainless-steel hose guide rollers. As with all Coxreels spring retractable reels, it features heavy gauge steel construction, durable CPC powder coat, rolled and ribbed discs, 2-year warranty, and USA made www.coxreels.com
Hydraulic Noise and Shock Suppressor
Wilkes and McLean manufactures an In Line Noise and Shock Suppressor for hydraulics and is a stocking distributor of Nacol Accumulators. Our suppressors eliminate pulsations, which greatly reduces noise and vibration from applications from a few gallons up to 200 gallons. We stock all of our suppressor sizes as well as Nacol Accumulators and parts from 1/5 of a pint up to 15 gallons, in our Schaumburg, Illinois facility. 877.534.6445 | info@wilkesandmclean.com | www.wilkesandmclean.com
Talk to your account rep or visit fluidpowerjournal.com/advertise
CONTAMINATION CONTROL
Routine and scheduled maintenance of hydraulic systems are vital to getting the most out of your Hitachi Mining Excavator. While maintenance plays the largest role in the prevention of unnecessary machine downtime, it can also expose the hydraulic system to high levels of contamination rapidly decreasing component longevity. The importance of contamination control is sometimes overlooked when performing maintenance due to incorrect practices being used.
THE FLANGELOCK™ TOOL AND CIRCUIT BLANKING CAPS
The FlangeLock™ tool and caps are the ultimate contamination control tools for protecting your hydraulic system. The FlangeLock™ allows for the simple sealing of open hydraulic flanges without tools while the caps can be bolted in place of a flange connection. Easy on, easy off, they offer a leak-proof solution to hydraulic systems and environmental cleanliness. FlangeLock™ tools and caps stop the mess.
HITACHI MAKING CONTAMINATION CONTROL EASY
Hitachi have packaged FlangeLock tool and caps specifically for Hitachi mining excavators. The Hitachi customised kits make sure no matter which component routine maintenance is being performed on, you will always have the exact number of FlangeLocks™* and caps to help reduce contamination.
*Note: FlangeLocks™ are not to be used under pressure
Call you local Hitachi Muswellbrook representative or the branch on 02 6541 6300 for more information.
PRODUCT SPOTLIGHT
Think Yates Cylinders for ALL of your cylinder needs!
Custom Welded Cylinders:
• 1.5” up to 50” bore, with strokes exceeding 300”
Heavy Duty Mill Cylinders:
• 1.5” up to 50” bore, with strokes exceeding 300”
NFPA/JIC Tie Rod Cylinders:
• 1.5” up to 24” bore; interchangeable with all brands
Yates Industries (HQ)
586.778.7680
Yates Cylinders Alabama 256.351.8081
Yates Cylinders Georgia 678.355.2240
Yates Cylinders Ohio 513.217.6777
Don’t Compromise – That hydraulic flange you want may be at MAIN
MAIN stocks 10,000+ hydraulic flanges and manufactures components in 4-7 days in the USA. SAE J518 Code 61 and J518 Code 62, JIS, DIN, ISO 6162, ISO 6164, and specials with socket-weld, buttweld, ORB, BSPP, etc.; all geometries, flange heads, flange adapters; in carbon, stainless, cupro-nickel, ductile, aluminum, etc. Sixty years’ experience plus SAE and ISO technical committee experience.
MAIN Manufacturing Products, Inc. 800.521.7918 https://mainmanufacturing.com/block-categories »
Have Your Machines Shine Contamination Monitoring Products
CML4
Compact portable monitor with internal sampling pump providing fast, accurate fluid analysis whenever needed.
ICS Mobile Version
Big performance in small package – permanently mounted for continuous online monitoring.
LPA3
The World’s most advanced and versatile contamination monitor, ensuring production and system cleanlines.
Young Powertech, Inc 9, OBC 610-558-0760 youngpowertech.com
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