Metal Work ISO 6432 pneumatic air cylinders offer an ideal solution for metric applications where an inexpensive actuator is desired. They feature a magnetic piston for position sensor compatibility.
• Double-acting models are interchangeable with other common brands of ISO 6432 cylinders
• Bore sizes from 12mm to 25mm
• Stroke lengths from 50mm to 300mm
• Universal mount dependent on accessories selected to include: foot mount, rod clevis, rod eye, rear clevis, pivot mount, and flange mount
• Chamfered 304 stainless steel barrel
• 145 psi maximum operating pressure
starting at $151.00 (W143016A010N)
NEW! Metal Work Dual Guide Rod Cylinders
Metal Work heavy-duty metric dual guide rod cylinders are ideal for applications requiring precision mounting and tolerance to a sideload. These cylinders feature magnetic pistons, bronze bushings, anodized extruded aluminum alloy housing, and switch mounting tracks.
• Interchangeable with other common brands of metric guide rod cylinders
• Bore sizes from 16mm to 63mm
• Stroke lengths from 10mm to 400mm
• Double-acting
• Maximum operating pressure of 145 psi
• Maximum sideload of 10N to 250N
Mary C. Gannon • Editor-in-Chief
Using the 55:5 rule to reset and perform better
SINCE I’VE LEFT THE NFPA Annual Meeting back in mid-February, I’ve been going, going, and gone — between several project deadlines and event after event with my family and work, I’ve barely stopped moving. This has caused me to have a real tunnel vision the last few weeks, sitting at the desk and not looking up much.
We all know this isn’t healthy, so I’m circling back to the NFPA closing presentation from Suneel Gupta, with his simple concept to reset and become more energetic, focused, and productive. Gupta — an American entrepreneur, author, television host, and keynote speaker — knows a thing or two about productivity.
The 55:5 principle suggests you complete 55 minutes of focused work, followed by 5 minutes of real rest. Not scrolling or catching up on email. Actual rest, which can be a quick walk out in the sunshine, closing your eyes, or stopping to make coffee. Anything that takes your mind off work for just five minutes.
In a world of back-to-back meetings, tight deadlines, and constant pressure to do more with less, carving out five minutes every hour sounds like a luxury most of us can’t afford. But after a month of nonstop deadlines, I’m thinking my brain, my eyes, and my soul could use that little break.
We need to rethink rest. As Gupta noted, we feel like we must earn rest through hard work. Once our inbox is clear, or the deadline has been met, we can breathe. But the inbox is never empty and there will always be another deadline. We do not do our best work when we’re exhausted though. The 55:5 principle means that rest is not a reward for our efforts.
It’s charging you to do better.
That distinction matters, especially where precision, creativity, and problem-solving are everything. The quality of your thinking is directly tied to your energy. And we all know energy isn’t infinite. It needs to be managed just as deliberately as time.
Gupta shared some of the research behind this concept and it was eye-opening. In studies measuring brain activity and performance, individuals who took short, intentional breaks throughout the day didn’t accomplish less; they maintained a higher level of performance and ended the day in a similar mental state to how they began. Meanwhile, those who powered through without breaks often logged more total “work time” but saw their effectiveness steadily decline. By the end of the day, they were mentally exhausted, less creative, and more prone to errors.
If you think about that in the context of our industry, it’s not hard to see the implications. How many design revisions, troubleshooting missteps, or communication breakdowns are really the result of fatigue rather than capability? In our industry, we are super focused on efficiency but rarely apply that same lens to ourselves.
The 55:5 model doesn’t ask you to rethink your entire schedule or find hours of extra time. It simply challenges the notion that every meeting needs to be a full hour, or that work should stretch until you’re mentally drained. I’ve thought about this often with my children, who I believe need more play time for recess. All they need to do is shave one or two minutes
from each class, and they’ve suddenly gained more than 10 minutes of extra outside time.
The key, though, Gupta stressed, is intentionality. The rest can’t just be a distraction. It must be about recovery. These small resets signal to your body and mind that it’s okay to downshift, even briefly.
The importance of preventing a burnout extends from productivity into leadership and team dynamics. The mindset you bring into a conversation — focused or scattered, calm or stressed — affects how others respond, collaborate, and contribute. This means that managing the energy you bring to work isn’t just personal. It’s professional. Taking five minutes to reset before walking into a meeting, a plant floor discussion, or even heading home at the end of the day can change the tone and outcome of the interactions we have with others.
This is why the 55:5 principle helps us to show up as our better selves at home and work. It builds recovery into every hour, rather than waiting for the end of the day, the weekend, or the next vacation. That’s why, now that I’m done writing this editorial, I’m vowing to set that 55-minute timer and start now. Will you? FPW
Electrohydrostatics has evolved over the last four decades from its beginnings in aviation to uses throughout more industrial applications.
24 CONTAMINATION CONTROL
How do clogged filters impact a fluid power system?
Clogged filters, while sometimes able to catch more contaminants, increase pressure drop, sending the filter into bypass.
28 PNEUMATICS
Lower compressor energy consumption with low-cost machine adjustments
These changes can unlock plant-wide air savings, avoid major capital investment, and improve carbon footprint.
34 MOBILE HYDRAULICS
Sealing considerations for mining applications
Keeping contamination at bay and protecting cylinders in mining applications requires careful selection of hydraulic seals.
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Is your hydraulic system overdesigned?
I ONCE CONFIGURED a hydraulic power unit for an automotive customer that had so many components attached and installed that it looked like the engine bay on a new BMW M5 with the plastic cover removed. I used the word "configured" rather than "designed" because the end customer had a Functional Requirements Specification document that was over 30 pages long — it didn't leave me much guesswork other than how big everything was going to be.
I mean, this thing had an oversized, elevated reservoir with an electrically monitored, locking ball valve at every fluid port, and pressure, return, and kidney loop filtration with a desiccant breather. Of course, the pressure filter was a duplex design that could be switched during operation, and every filter had electrically monitored bypass indicators.
When you run an elevated reservoir, a locking ball valve is just plain smart — with a 2-in. suction line, that eye-level tank can drain faster than a nepo-baby’s trust fund. But when your locking, monitored ball valve costs more than the kidney loop pump you’re protecting from cavitation, maybe you’ve overdesigned your
hydraulic system.
Don't get me wrong — the customer paid good money for their excess, and as a hydraulic designer myself, it's fun building a cost-noobject power unit. And if you're one of my own customers reading this, look away now, because a power unit made for a third of the price would have worked just as well. Instead, excessive capital investment displaces net profit, while providing only marginal benefit to the production line.
And while we’re at it, can we stop with all the just-in-casing? I've been guilty of recommending this in my missives, so that just shows you how widespread our thinking is. Say we build a circuit with a required 25 gpm, but because we couldn't get the precise displacement for that volume, we go one size up in the manufacturer's catalog. Great, we now have 30 gpm capacity, which, for a fixed pump running 3,000 psi, is wasting nearly nine horsepower if we try to force this through a priority flow control (which none of you are dumb enough to do, right?).
Okay, okay, nobody's going to do what I mentioned, I know. Because gear pumps offer
finer displacement increments, such excess is unlikely unless you move up to a piston pump with coarser steps to choose from. Regardless, most piston pumps have max volume adjustment, so you don't have to settle for the extra displacement.
My point is, have you ever tried to under-design something? Seriously, what would happen if you had just barely enough for everything? Try selecting an efficient pump design that’s barely enough flow rather than a hog that wastes 20% of your energy. Instead of multiple filter locations, what about a single, low-micron, high beta ratio return filter? Rather than oversizing the plumbing, make it "big enough" and realize the machine only runs at 80% of its max capacity, anyway. How about, instead of buying enough food for an Italian wedding, we get just what we need for the party and accept that we might run out? Sorry, that last one was for my wife.
Overdesigning has effects that compound in the form of higher initial investment, extensive maintenance, or irresponsible use of fuel or electricity. So when you're designing your next system, stop and think about whether you're buffing it up for the sake of it, and that every decision matters to cost and performance. Otherwise, you’ll end up like the new BMW M5, which is 1,000 lb heavier than the old model and slower to 60 mph despite having three digits more horsepower. FPW
Josh Cosford • Contributing Editor
Josh Cosford • Contributing Editor
THE BMW M5
From the original STAUFF Pipe Clamps to our Metric Tube Fittings and Quick Release Couplings STAUFF offers port-to-port hydraulic solutions, components, and accessories for hydraulic systems and applications.
STAUFF is your trusted source for industrial and mobile fluid power components and solutions worldwide.
Metric Fittings
Pipe Clamps Filtration
Mary C. Gannon • Editor-in-Chief
Compact offline filtration systems clean up gearboxes
KIDNEY LOOP
FILTRATION
SYSTEMS are designed to filter fluid from large systems, and are usually made up of a continuous filtration machine on a portable cart that allows users to transport them from machine to machine. But on smaller systems, these portable designs might be overkill.
For smaller hydraulic systems, gear boxes, or diesel fuel systems, a unique and patented design from FluidLoop Technologies LLC of Gig Harbor, Washington draws off small amounts of working fluids and circulates them through a filter to remove particles and/or water. The FL-1000 system can be fixed or portable and moved from equipment to equipment; and can circulate and filter fluid even when machinery is idle or shutdown.
The compact product with carrying case is only about 18 in. long by 8 in. wide, and can pump up to 1 gpm, said Don Brown of FluidLoop.
The patented system uses a specialized
miniature dc-powered variable speed pump/ motor combination that draws only a fraction of a horsepower. The unit can be tank- or wallmounted and comes with an optional hand carry stand. It can be run off a standard 120-V outlet with a factory supplied dc converter or a standard dc power supply.
Gearboxes, which are considered some of the most heavily contaminated systems in industrial use, benefit most from low-flow, or offline filtration. Unlike high-flow, in-line filtration systems that must balance flow demand with filtration efficiency, low-flow filtration prioritizes contaminant removal efficiency and continuous oil conditioning. This approach is especially advantageous for gearboxes with relatively small sump volumes and high oil viscosities.
Low flow filtration allows oil to pass through the filter media at reduced velocity, significantly improving particle capture efficiency. This enables the use of fine, high-efficiency media (1–10 µm and below) without causing excessive pressure drop.
“Many gearbox people want to polish up the oil, because they often don't filter down clean enough. The Fluidloop unit was designed to add on permanently and it can run 24/7,” Brown said.
He also noted that the system can be carried easily from machine to machine as well, as it comes with an aluminum carrying unit bracket.
The variable speed pump allows the FL-1000 to be easily adjusted for use on different viscosity fluids and different tank sizes. The pump/ motor is mounted to the filter head, and the system can accommodate a wide range of filters using factory supplied adapters.
The FL1000V2 delivers controlled low flow rates (up to approximately 0.67 gpm depending on viscosity, temperature, and filter selection). It can provide continuous offline filtration without aeration or disturbance of settled contaminants. Its stainless-steel, variable-speed, high-torque pump allows precise adjustment
for different oil viscosities and operating temperatures. This is critical for gearboxes using ISO 150–460 oils, where fixed-speed pumps often struggle or generate excessive pressure.
The system supports a variety of high-efficiency spin-on filtration options including 2 and 4-µm synthetic media filters for fine particulate removal, water-removal filters for moisturesensitive gearbox applications, and 1-µm depth filters for fine particulate and water removal. This flexibility allows users to tailor filtration performance to specific gearbox requirements and contamination risks.
Nick Reslin, who developed the technology, said he started studying sawmill systems that had failed due to contamination. “I got curious
about what was controlling the life expectancy, so I started a laboratory to do oil analysis, and I was seeing that the systems that I was designing and installing were typically 10 µm filtration,” Reslin said. “Most of our competitors still use 10 µm as the standard. That’s why I came up with a 1 µm filter in a kidney loop. We would take a small amount of oil, polish it off on the side, and when we did oil analysis again, we saw that the oil was way cleaner.”
Reslin tested it at a sawmill which had previously seen continuous failures. With the 1-µm filtration, they stopped failing and ran optimally. He also tested the machine on the Port of Tacoma, Washington’s hydraulics and its engines, which allowed them to increase time between overhauls from 9000 hours to up to 25,000 hours. They then started using the system on gearbox cranes, which also saw reduced failure times.
Reslin developed a custom spin-on filter head and adapted the variable speed pump motor design to the spin-on filter head. He also created adapters to allow for custom use on the system. This allowed for quick and easy installation that can be done in less than hour, even without shutting down the line, Reslin said.
With numerous units in service since introduction, they believe that there are hundreds of thousands of gear box and small hydraulic systems up to about 100-gal reservoirs that can benefit from this low-cost filtration system. Benefits include improvement in equipment life, reduced maintenance and down time, extended fluid drain intervals and reduced fluid disposal costs. Applications could include pulp & paper mills, industrial machinery, agricultural equipment, mining equipment, marine vessels, and wind turbine gear boxes, among others.
For example, Brown said that in one logging veneer plant, contamination was causing catastrophic failures of the high-speed actuators that help peel the logs. Lack of gear oil filtration on high-speed actuator assemblies required frequent rebuilds and mill downtime.
The actuator assembly has a tube with screw and cycles approximately 8,000 times per day when the mill is running. It uses approximately 3 gal of gear oil, with oil temperatures running approximately 110-120°F (43-40°C). It previously had no filtration and required actu-
ator rebuild about every six months.
Prior to filtering, an oil analysis report showed abnormal contamination and fluid condition, with ISO Codes of 25-25-24. They installed a Fluidloop FL1000 Filtration system (on Actuator #1) with a 1µ depth filter designed
to remove both dirt particles and water from the gear oil; thereby reducing rebuilds on the actuator and unplanned mill downtime. A second Fluidloop FL1000 was installed on the second #2 Actuator a couple months later.
Installing FluidLoop technology quickly cleaned the units and got them back running. Fluid sampling was done before/at installation, after one week, and after five weeks. Improvements in oil cleanliness were almost immediate. Prior to filtering, ISO Codes were 25-25-24. At one-week the ISO Codes improved to 23-20-15, and at five-weeks, they dropped to 18-16-12.
It is estimated that in a period of 18 months actuator rebuilds will be reduced from six planned to two. This will result in a cost savings of $56,000 – $64,000. Additional savings are estimated by the reduction of unplanned downtime, gear oil replacement, and disposal costs. FPW
FluidLoop Technologies LLC fluidlooptech.com
Paul Heney • Vice President, Editorial Director
HUSCO steers innovation through CONEXPO
AT THIS YEAR’S MASSIVE CONEXPO SHOW, Waukesha, Wis.-based component manufacturer HUSCO showed off its steer-by-wire (SbW) platform called GenSteer, which was selected as the “Next Level Award winner” in the Equipment category at the show.
GenSteer eliminates redundant electronics and costly backup systems by instantly switching to operator powered control during faults, making digital steering practical and scalable while delivering fail functional safety for offhighway OEMs.
Simon Yardley, Director of Business Development & Corporate Marketing for the company, along with Ben Holter, Product Director, Mechatronics, provided details at a live press conference at the show, where they explained how GenSteer represents a giant leap forward for the evolution of steer-by-wire for the construction, agriculture, mining, and material handling industries.
Holter explained that steering is on everything from marine vehicles to off-highway machinery to automotive. And many people think steer-by-wire electronic assist steering exists today in these applications, but it actually doesn’t.
“There are very few examples today in the
market of a road safe steer-by-wire system,” he said. “They all have a physical link from the operator to the steering axle. Now that physical link can be a linkage, it can be hydraulics, it can be electroover-hydraulic — but there is always a physical link, and that presents two huge challenges.”
“One is the complexity. Imagine how in some machines the operator is a long way from the actual steering axle, so that makes it very difficult. And when you want to bring extra modes or extra features, it’s really complicated to have to add components, add more bits, more widgets, to make it as safe as the current system,” explained Holter. “We’ve seen advancements in other parts of vehicles. The throttle used to be a cable that went to the engine, but now it’s all pretty much electronic, so that you can get advanced features and maximize the engine.”
Bringing advanced, smart and even automated steering to off-highway machines has long come at a cost—literally and figuratively. Traditional hydro-mechanical systems rely on orbital valves, and current “add-on” electrohydraulic manifolds that simply bolt automation
onto old architecture. It works, but it’s bulky, inefficient, complicated and only qualified for field use—not the road.
Full SbW systems replace mechanical and hydraulic linkages entirely with electronic control. They meet on-road safety standards, but only through high redundancy and sophisticated feedback hardware, making them expensive and complex to implement. Between these extremes lies a gap the industry has yet to close: a safe, simple, and scalable path to off-highway SbW.
Instead of duplicating controllers, batteries, and software to meet safety standards, GenSteer reimagines the steering control unit from the ground up. It uses the operator’s own input as a fail-functional power source, just like traditional hydraulic orbitals. If a fault occurs, the system seamlessly transitions to operator-powered control with no lag, no loss of steering, and no backup electronics required.
In normal operation, a force-feedback motor delivers real steering feel while electro-hydraulics control the wheels. During an electrical fault, GenSteer instantly becomes a generator, converting operator input into electrical power to
MARY
GANNON HUSCO
HUSCO'S CONEXPO GENSTEER DEMO UNIT ALLOWED USERS TO SEE THE FAIL-FUNCTIONAL FEATURE OF THE TECHNOLOGY, SO THAT IF YOU LOSE POWER, YOU CAN CONTINUE TO STEER YOUR VEHICLE TO SAFETY.
HUSCO’S GENSTEER FAILFUNCTIONAL STEER-BYWIRE PLATFORM ALLOWS USERS TO ENHANCE SAFETY.
control the hydraulic valve and maintain steering. This approach preserves trusted safety while unlocking digital control.
GenSteer removes the trade-off between cost and capability. OEMs gain a scalable SbW architecture that:
• Preserves the inherent safety of legacy hydro-mechanical systems.
• Unlocks advanced features like lane guidance, return-to-center, and haptic feedback via software updates, not hardware overhauls.
• Reduces complexity and cost by eliminating redundant controllers and backup batteries.
“The GenSteer platform is designed to start simple and scale with you. OEMs don’t need every automation feature on day one to justify the investment,” Holter said. “Begin with a compact, compatible steering platform, then add capabilities like lane guidance, return-to-center, and haptic feedback as your needs evolve. It’s a practical on-ramp to Steer-by-Wire—without the heavy bill.”
Key benefits of the technology include
• Safety: Maintains control through faults. No surprises, no downtime.
• Cost: Eliminates redundant controllers, batteries, and complex harnesses.
• Future-Proof: Ready for software-driven feature drops without hardware changes.
• Sustainability: Fewer components mean less material waste and e-waste.
• Workforce: Digital performance tuning reduces fatigue and enhances operator safety.
Husco wants to allow machinery manufacturers to maximize today’s lesser skilled workforce, but also to give superpowers to the experienced workforce.
“We want to bring innovation within the cabin, and there’s a lot of different features where, once you’ve broken that physical link between the operator and the steering axle, then you can really start bringing in these incredibly cool features,” Holter said.
The product is designed to give OEMs a prac-
tical, scalable foundation for modern steering features, without the high complexity or costly redundancy that have historically slowed industry adoption. GenSteer enables:
• software-defined upgrades without the need to change hardware,
• redundancy without replication for true failfunctional safety,
• drop-in integration with minimal machine redesign, and
• a direct path to digital steering across all wheeled equipment.
“GenSteer is one of those rare innovations that immediately changes the conversation around steer-by-wire adoption in off-highway applications. Being named a Next Level Award finalist tells us the industry sees the significance, too. This isn’t an incremental improvement; it’s the beginning of a new era for digital control across all wheeled equipment,” said Holter. FPW HUSCO husco.com
The Gold Standard in Live Swivels.
Ron Marshall • Contributing Editor
How one steel plant saved thousands
THE STEEL PLANT HAD BEEN RUNNING ITS compressors at 120 psi for as long as anyone could remember. The air system was powerful and reliable, or so it seemed. But when energy costs started climbing, management called in a compressed air auditor to see if there were hidden savings.
When the auditor arrived, he didn’t bring promises of shiny new equipment. Instead, he began with one simple question: “What pressure do you actually need to run production?” The maintenance manager shrugged. “We’ve always used 120 psi; it keeps things safe.” The auditor smiled. “Maybe. But let’s find out what it’s costing you.”
Using a few strategically placed gauges, the auditor tracked pressures throughout the system, from the compressor room to the far end of the plant. He found something interesting. Although compressors delivered up to 125 psi, many of the tools and machines on the floor only needed 90 psi to operate properly.
The difference came down to pressure drop — these are losses caused by undersized piping, clogged filters, and poorly maintained regulators. These restrictions forced operators to keep compressor discharge higher just to maintain adequate pressure at the end-use points. “Instead of running the whole system at high pressure,” he explained, “let’s fix the restrictions so we can safely lower it.”
Over the next few months, the maintenance team followed his plan. They cleaned filters, checked piping, and added a pressure/flow controller along with an extra air receiver to handle surges. Then, together, they slowly began lowering the system pressure in small increments, monitoring every step. To everyone’s surprise, production didn’t notice a thing. Machines ran smoothly, tools had plenty of power, and the compressors ran less often.
After a while, the system stabilized at 90 psi, with the compressors delivering 100 psi. Power meters told the story clearly: energy use had dropped by almost 13%.
“Every 2 psi we drop saves about 1% on power,” the auditor reminded them. “And you’ve just reduced by 25 psi.”
Better yet, the compressors cycled less frequently, meaning less wear and fewer maintenance issues. What started as a cost-saving project had turned into a reliability upgrade as well.
At the year-end production meeting, the plant manager proudly shared the results: lower energy bills, steadier pressure, and happier operators. The maintenance manager laughed and said, “All we did was turn the knob the right way.” The auditor smiled. “That’s the thing about compressed air systems, sometimes the biggest savings come from using less of what you already have,” he said.
By learning to question “the way we’ve always done it,” the steel plant saved thousands each year but also gained a more stable and efficient system. The lesson was simple yet powerful: measure, understand, and adjust. The right pressure isn’t just about keeping machines running, it’s about keeping money from escaping with every unnecessary psi of air.
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Mary C. Gannon • Editor-in-Chief
NAHAD mixes its annual meeting up in Indianapolis
NAHAD
HAS MOVED ITS ANNUAL MEETING TO INDIANAPOLIS, AS IT SEEKS TO EXPAND THE EVENT WITH A MORE CENTRAL LOCATION.
FOR ITS 42ND ANNUAL MEETING this year, NAHAD has switched things up, moving the event to JW Marriott Indianapolis, May 16-19. It appears this move to a more central location is attractive to members, as the 2026 Annual Convention is on track to be the largest event in NAHAD history, bringing together a record number of industry professionals in one place.
NAHAD Executive Vice President Molly Alton Mullins said that NAHAD’s board of directors wanted to approach this year’s Annual Convention a little bit differently. “We chose Indianapolis as the location in an effort to encourage NAHAD member companies to bring more of their teams to a desirable location. Indy is drivable for many NAHAD members; the JW Marriott, while exceptional, is also more affordable than a lot of previous NAHAD convention locations,” she said. “By choosing a location like this, and
increasing educational content and programming, our goal was to attract more attendees across a cross-section of job function and title. And it’s working. We are trending higher attendance at this year’s convention over any other year in NAHAD history. And we have increased networking and collaboration opportunities as we hear from members often that is where they see the greatest value at the Convention.”
New this year will be the first in person segment of NAHAD’s LEAD Program, the association’s mentorship and leadership development initiative focused on preparing the next generation of hose industry leaders. Attendees will also benefit from expanded workshops, additional educational sessions, and a larger exhibit hall that provides greater access to the companies and leaders shaping the industry. The Annual Convention will offer unmatched opportunities to connect, col-
laborate, and build relationships with industry professionals across all levels of experience.
“In addition to increased programming, there will also be the launch of LEAD (Leadership, Exploration and Development), NAHAD’s new mentorship program. This program is designed to provide a format in which participants can learn and network with industry colleagues in an environment designed to improve industry knowledge and professional opportunities. This program kicked off earlier this year, and during this year’s Convention, attendees will have specific onsite trainings taking place, as well as direct mentor/mentee matchings to facilitate deeper networking opportunities,” Alton Mullins said. “Each year we’re trying to bring new value to the Convention that helps NAHAD member companies tackle everyday challenges impacting their businesses. I’m looking forward to hearing feedback from attendees on how we can continue to build value in each Convention’s programming and format.”
Speakers for this year’s event include the following.
• Michael Feuz from ITR Economics kicks off the opening general session with an overview of the economic climate.
• Annalise Koltai is an executive coach who has spent the last decade working with leaders at Fortune 500 companies including Slack, Salesforce, LinkedIn, Workday, Fidelity Investments, and OpenAI. She will present three workshops Sunday afternoon.
• Tracie Sponenberg is a business leader specializing in people, HR transformation, and leadership development. She is speaking on Monday, at the general session and breakfast, and hosting an afternoon workshop.
• Steve McClatchy is a keynote speaker and author of the award-winning New York Times Bestseller Decide: Work Smarter, Reduce Your Stress & Lead by Example. He is presenting on Monday at the Members Luncheon, and an afternoon workshop.
• Alex Weber will close the presentations on Tuesday morning. He is an award-winning keynote speaker, coach, author, TV Host for NBC, and competitor on American Ninja Warrior.
As in past, the NAHAD Convention will include a Manufacturers and Hospitality Night as well as the Showcase of Hose Solutions. Networking opportunities will include a welcome hospitality event, Emerging Leaders Orientation and Happy Hour, and opening reception on Sunday. On Monday, members will connect throughout the many sessions and luncheon as well as the manufacturers hospitality night. A special breakfast will be held Monday for Women in NAHAD. Special guest programming will also kick off Monday. Finally, Tuesday’s programming includes the general session and business meeting, Showcase of Hose Solutions, the LEAD Program, and the closing reception. FPW
Visit nahad.org for more details and to register.
Josh Cosford • Contributing Editor
Where does built-in contamination come from?
WHEN I SAT IN MY first fluid power class 18 years ago, I remember learning about built-in contamination and how the reservoir was the biggest offender. The welds and their slag were the biggest problems, the teacher stated, but a close second was the debris from pipe threading machines. Looking back, it’s clear those two sources should be top-of-mind when building a hydraulic power unit and subsequently assembling the rest of the circuit. However, it might be more precise to consider what stages of hydraulic machine fabrication the built-in contamination comes.
For example, the manufacturing stage for each subcomponent of your hydraulic circuit may birth its own form of built-in contamination. There is the weld spatter, slag and spatter balls that must be accounted for when fabricating hydraulic reservoirs, but remember that every other component was also manufactured. Pumps, valves, cylinders and motors come from
WELDING SLAG IS PRODUCED AS A BYPRODUCT OF SOME ARC WELDING PROCESSES AND IS A COMMON SOURCE OF BUILT-IN
CONTAMINATION.
allowing the paint chips to enter open ports.
Even as pumps, valves and cylinders are assembled, ancillary parts such as Teflon tape, seals, and O-rings may pinch, extrude or come loose, entering the circuit and causing possible headaches. Every assembly technician has accidentally pinched a cartridge valve or cylinder piston seal during installation, and bits may break off without notice, clogging passages or pilot lines.
Fabrication and installation are likely the biggest offenders to contamination standards.
factories where casting, forgings or billets are machined to their final shapes, and those processes create chips and particles detrimental to the longevity of those very same components.
You might be shocked to know that freight and packaging can add contamination to your hydraulic parts after they’re manufactured. Rust inhibitors or protective coatings will not likely harm anything in your hydraulic system, but packaging certainly can. Some heavy items, such as pumps, might be packed in Styrofoam, which could potentially enter the circuit where it easily clogs some pilot lines. And the port plugs installed prior to painting are prone to flaking,
Fabrication and installation are likely the biggest offenders to contamination standards. Welding brackets, supports, and drip trays create all the same issues as manufacturing reservoirs, plus threading pipe or cutting hoses certainly spew forth metal chips and dust that are not suitable for anything on this side of a log splitter. And in many machine assembly shops, you may experience airborne dust, paint particles or various forms of fallout from nearby factories.
We land on the final form of built-in contamination, which is both a boon and a bane on your hydraulic system. When many of the above built-in contaminants find themselves inside your hydraulic machine prior to startup, you may want to rinse and flush the system prior to final startup. However, in some cases, you may need to rinse the residual flushing fluid prior to machine startup.
If your machine is particularly contamination-sensitive, even a minute amount of dirtladen flushing fluid could damage expensive and precise components. In this case, it’s recommended you fill your machine with oil and circulate the system through an offline filter at very low pressure to carry about the last of the fluid and particles. FPW
C o n t a m i n a t i o n C o n t a m i n a t i o n
c r e a t e d d u r i n g c r a t r n g
h o s e f a b r i c a t i o n h o s e a b r c a t o n
r e m o v e s r e m o v e s
c o n t a m i n a t i o n c o n t a m n a t o n
pneumatics (or at least rarely), steel cylinders are, especially in the mill-type and NFPA constructions, and we know that steel just straightup rusts. Plus, even modern plants may still use cast-iron pipes for airline distribution, and it takes only a simple twist of the water-drain ball valve to see the rust-tainted condensation spatter your floor.
Still, with enough water, especially in a continuous state of contamination, moisture does affect performance. Even aluminum can oxidize over time, and some pneumatic seals are compatible with water. Equipment, such as air ratchets, air motors, and many cylinders, requires constant lubrication to prevent excessive wear, which is reduced or eliminated when water displaces it. And water can affect the performance of pilot-operated functions that rely on tiny holes remaining clear to transmit a pressure signal.
Of course, water in mobile systems is a different story, especially in cold climates. I don’t need to tell you that water freezes, and it can
Expect construction materials to be moistureresistant and to resist oxidation and corrosion, especially from within.
affect the performance of air cylinders on salter trucks, pneumatic tire inflation systems, and air brake systems. Freezing airlines or valves are an annoyance at best, but dangerous at the worst. This is why the components that constitute a pneumatic system must be able to handle not only moisture but also ice formation.
Expect construction materials to be moisture-resistant and to resist oxidation and corrosion, especially from within. Plastic, anodized aluminum, stainless steel, and even ceramic are all empowered to defend against the forces of evil and also allow pneumatics to maintain its respectable price point.
Manufacturers pay attention to small details to ensure reliability despite possible circulating or stagnating water. Galvanic corrosion occurs between two dissimilar metals, such as steel and aluminum, so any such combination is avoided by using similar metals. Should such unmatched pieces interface, designers will use rubber or plastic gaskets to prevent electron exchange. Of course, entirely different, non-conductive materials make great bedfellows, which is why ceramic spools are commonly used.
Moisture is ubiquitous in pneumatic systems, and because no drying system is perfectly efficient, cylinders, motors, and valves are designed to withstand even moderate amounts of water. Let's be clear: you should avoid excessive moisture by using appropriate drying equipment, as water can degrade performance. But rest assured that even the most budget-friendly air components are resilient in the face of moisture. FPW
OFFSHORE ACCESS SYSTEM (I.E., GANGWAY) FROM AMPELMANN IS UNDERPINNED BY A MOOG 6 DOF MOTION BASE USING ELECTROHYDROSTATIC ACTUATION. THE GANGWAY ALLOWS PERSONNEL TO TRANSFER FROM A SHIP TO, FOR EXAMPLE, AN OFFSHORE WIND TURBINE IN SEAS UP TO 3M HS. BECAUSE OF ITS FULL MOTION COMPENSATION, THERE IS NO MOVEMENT IN THE GANGWAY DURING OPERATION, RESULTING IN A SAFE WAY TO TRANSFER WORKERS. THE GANGWAY CAN TRANSFER 20 PEOPLE IN UNDER FIVE MINUTES FROM A VESSEL TO A FIXED OR FLOATING OBJECT.
High-flying
CONTRIBUTED BY BILL PERRY MANAGING PARTNER, MARCH 24 MEDIA LLC, ON BEHALF OF MOOG INC.
ELECTROHYDROSTATICS HAS EVOLVED OVER THE LAST FOUR DECADES FROM ITS BEGINNINGS IN AVIATION TO USES THROUGHOUT MORE INDUSTRIAL APPLICATIONS.
IN THE 1980s,
aircraft manufacturers began exploring ways to eliminate the potential leaks from hydraulic lines and gain efficiency in energy transfer. Electromechanical actuation wasn’t an option because the industry didn’t want to risk primary flight controls failing. So, the aircraft industry began using electrohydrostatic actuation for flight controls. An electrohydrostatic actuation system, or EAS, works like electromechanical actuation with a bidirectional motor controlling linear or rotary motion, yet mirrors a hydraulic system with a hydraulic transmission transferring motion. The electric servomotor drives a bidirectional, variable-speed pump connected to a single- or double-rod hydraulic cylinder. The cylinder speed is directly proportional to the pump’s flow rate, so by changing the pump’s rotation speed you can control the actuator’s movement. The energy or power demand is loaddependent without any inherent losses. Engineers can integrate a hydrostatic drive into a very compact unit with a completely self-contained hydraulic circuit, which appealed to aircraft makers.
Eliminating the central hydraulic power unit (hpu) as well as hoses, pipes, and couplings and integrating traditionally separate components for hydraulic drives offer advantages over a conventional hydraulic solution. The heart of the EAS is an electrohydrostatic pump unit (epu), which comes in various designs and sizes. There are also linear and customized EAS. Whether a design engineer chooses to use certain components, or an entire EAS, depends on the application. For example, an engineer might choose the:
1. EPU alone; the EPU is the system’s core component, and ranges in size from 5 to 140 cc. Implementing this requires a lot of hydraulic/electronic know-how.
2. EPS, which is the EPU plus the manifold. This is an entry-level sub-system with the highest flexibility for various applications and requires some electronic know-how.
3. EAS, which is the EPU plus manifold and cylinder; this offers a self-contained actuator and is a turnkey solution requiring no special know-how.
An EAS solves many motion control challenges that aircraft makers and industrial machine designers wrestle with:
• energy efficiency,
• limited installation space,
• safety requirements,
• shock resistance against pulsation,
• lack of hydraulic know-how,
• environmental cleanliness,
• noise emissions,
• high forces, and
• backlash.
For example, the EAS has been adopted by manufacturers like Ampelmann, a provider of high-tech offshore gangways; Meritor, an automotive supplier; Plastic Metal, an injection molding machine maker, and Frey & Co. GmbH.
In its offshore motion-compensated gangways, Ampelmann uses electrohydrostatic actuation to combine the high force density of hydraulic cylinders with the efficiency and controllability of electric drives. The system replaces a traditional centralized hydraulic power unit and valve-controlled circuits with an EAS. In the gangway’s hexapod motion-compensation platform, hydraulic cylinders remain the primary actuators because they can generate the large linear forces needed to stabilize the gangway. Each cylinder is paired with its own electrohydrostatic actuator consisting of a motor-driven pump unit. By varying pump speed, the actuator directly controls flow to the cylinder at the exact load pressure required, eliminating the throttling losses typical of valve-controlled hydraulics. The closed-loop hydrostatic circuit also allows the pump unit to operate in four-quadrant mode, recovering energy when the cylinder retracts and feeding it back into the system. This architecture dramatically improves efficiency and reduces system size. It requires
less than a fifth of the amount of hydraulic fluid previously needed, lowers energy consumption and reduces the gangway’s input power demand by 90%.
Germany-based Frey & Co. sought an EAS to replace the hydraulic system in its EasyISO2000, which is a 4000-kilonewton isostatic press. Frey’s press produces ceramic parts by applying high pressure to ceramic powder in a sealed elastomer container, shaped specifically for the application. The press’ original design included a traditional hydraulic system for five axes but required frequent maintenance. The design consumed high levels of energy, too. The original hydraulic design included a hydraulic power unit (hpu) with pump, filtration and cooling — all based on conventional hydraulics. The EAS adopted by Frey & Co. includes a function block and integrated, energy-saving EPU to control the machine’s five press axes. The EPU is five to 10 times smaller than the HPU. The EPU also includes smaller filtration and cooling mechanisms, so the press uses less oil, has fewer maintenance points, and is more stable.
Since the EAS is a closed system, there is no pressure drop, and that translates into energy savings for the EasyISO2000. The EAS is also a direct-drive system between the cylinder and the pump. The original design had a 250-cc HPU and an oil tank measuring 400 to 500 liters; the design also required the system to cool oil, which draws additional energy.
The new design with the EAS has a 70-liter oil tank reservoir and 32 cm3 EPU. With the EAS’ smaller tank there’s less need for cooling.
The EAS controls the main axes of the EasyISO2000 press and all additional tool axes. The solution also includes a manifold assembly, accumulator, and a small auxiliary power unit.
The EPU running with the EasyISO2000 is a four-quadrant pump made by Moog, with a compact design and interface enabling direct mounting on a manifold; this minimizes the space required on each axis.
The four-quadrant pump offers power-ondemand, which reduces operating costs. An EPU like this can reduce oil demand by 90%, providing an ecofriendly and safe power unit. Moog designs and manufactures these EPUs as fixed, dual and variable displacement units with digital control to cover different cylinder sizes, loads, and process cycles across an array of industrial applications.
FOR OTHER INDUSTRIAL APPLICATIONS, MOOG INTRODUCES ITS EPU-G
For applications with smaller pump volumes, Moog introduced its EPU-G, which
is available in sizes as small as 5 cm³. This adds smaller pump volumes to an EPU product range spanning from 19 to 140 cm³. Equipped with a four-quadrant internal gear pump and servomotor, the EPU-G is for applications with volume flows as low as 10 lpm. The EPU-G’s variable speed and power-on-demand operation reduces noise emissions at partial load and lowers energy consumption leading to a reduction of operating costs. With high dynamics, low inertia and minimal pulsation at variable speed, the EPU-G improves the overall performance of industrial machines.
Examples of industrial applications where the EPU-G fits are process valves; gas, steam, and water turbines; transportation; renewables (e.g., adjusting solar panels); and pulp and paper presses.
RECOMMENDING THE BEST TECHNOLOGY, NOT ONE SYSTEM
Moog offers several options to meet the needs of machine developers: electromechanical actuation, hydraulic actuation and EAS. So, Moog’s engineers pair an application with the best technology instead of advocating for a particular system. That said, opting for an EAS (versus other technologies) offers several benefits including:
• A decentralized motion control technology without servo or proportional valves reduces oil requirements by up to 90%.
• A self-contained system eliminating hydraulic hoses, which reduces installation and maintenance time by two to three days on average.
• Removing the central hydraulic system reduces the weight and size of the system by up to 50%, so machine builders and integrators can install within smaller spaces.
• Streamlining the hydraulic circuit simplifies planning and reduces potential sources of faults and leaks; this boosts reliability and makes maintaining the whole system easier.
• The connected servomotor and hydraulic pump — without coupling and bell housing — is impervious to pressure surges and nearly wear-free, even in continuous operation.
Generally, the retrofit and transition to an EAS pays off for machine operators within a few years. A reduction in maintenance and energy costs over ten years of operation reduces the total cost of ownership, or TCO, meaning the upgrade pays for itself after two to three years on average. The result: an industrial machine combining the power density of electrohydraulics and the efficiency of electromechanical actuation. The benefits of earlier EAS for aircraft now bring a high-flying payback for industrial machinery too. FPW
Moog Inc. moog.com
A CLOSE-UP PHOTO OF THE MOOG 6 DOF USED ON THE OFFSHORE ACCESS SYSTEM (I.E., GANGWAY) FROM AMPELMANN.
A PRESSURE FILTER ON A VALVE MANIFOLD IS DESIGNED TO FILTER OIL TRAVELING TO THE VALVE, PICTURED. THE BYPASS INDICATOR IS CURRENTLY SHOWING GREEN, WHICH MEANS THE FILTER HAS PLENTY OF LIFE LEFT.
HOW DO
CLOGGED FILTERS IMPACT A FLUID POWER SYSTEM?
BY JOSH COSFORD, CONTRIBUTING EDITOR
CLOGGED FILTERS, WHILE SOMETIMES ABLE TO CATCH MORE CONTAMINANTS, INCREASE PRESSURE DROP, SENDING THE FILTER INTO BYPASS.
A FEW YEARS AGO, I BROUGHT MY VEHICLE into the dealership for servicing, and while I waited, I watched the TV hanging from the wall behind the counter. It was a reel of service schedules, recommended replacement items, and some other upsell commercials.
One such video showed a cutaway of a vehicle HVAC system, first with a brand-new cabin filter, and an animation of fresh, baby-blue, breezy air flowing freshly into the cabin. They contrasted it with a clogged filter apparently pulled from a dump, where the air flowing into the cabin appeared more like green puffs of toxic dog farts.
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When I mentioned to the service advisor that filters don't work that way and that a clogged filter would likely yield fresher air, she looked at me like I was reciting the first few thousand prime numbers. When I broke the long silence with, "…maybe it would flow less air, though," she responded dryly with, "What's the best number we can reach you at?"
Regardless, it’s easy for the fluid power layperson to misunderstand the fundamentals of filtration, because a clogged filter is actually more efficient at removing both more and finer particles from your hydraulic oil. A partially loaded filter accumulates debris on the surface or in the depths of the filter element, blocking pores and reducing the number of paths for particle-containing fluid to pass. A bunch of 6 micron particles blocking a bunch of 5 micron pores will prevent anything larger from passing and then likely get stuck on the surface.
CAN A CLOGGED FILTER REALLY BE A GOOD THING?
As contamination builds to high levels, a layer of cake can form, and the cake will trap even more fine particles. Of course, cake increases pressure drop exponentially, so it's likely that a return line filter would have gone into bypass long before this. A filter bypass valve is a spring-offset check valve that starts to open as pressure drop increases due to dirt resisting flow across the filter media.
If your filter is in bypass, even just a little bit, you're passing entirely unfiltered fluid. In this case, a clogged filter is much worse, so it's important to monitor a filter's differential pressure using pressure gauges, indicators, or electrical switches/lights. Differential pressure is a specific type of pressure measurement that compares two locations; in this case, the pressure before the filter and after the filter.
We often casually refer to the above differential pressure measuring devices as their clogging indicators, which are designed to signal that the filter should be changed when the pressure reading is around two-thirds of what the bypass valve will open at. This gives you time to
ALTHOUGH A DIRTY AIR FILTER MAY NOT SEEM LIKE IT’S GOING TO CLEAN THE AIR IN AN AUTOMOBILE, IT WILL TRAP MORE DIRT PARTICLES BECAUSE A PARTIALLY LOADED FILTER ACCUMULATES DEBRIS ON THE SURFACE OR IN THE DEPTHS OF THE FILTER ELEMENT, BLOCKING PORES AND REDUCING THE NUMBER OF PATHS FOR PARTICLECONTAINING FLUID TO PASS.
purchase a spare filter element and have it installed. Just keep in mind that cold hydraulic systems with cold hydraulic oil will appear to show a more clogged filter during machine startup.
THE DANGERS OF BYPASS
If your hydraulic filters have reached bypass, a range of issues can impact the performance of your machinery. You must know the signs of a clogged hydraulic filter and why it’s essential to address this problem promptly.
A noticeable decrease in the performance of your hydraulic system is one of the first signs of a clogged filter. You might observe slower or jerky movements, decreased lifting capacity, or reduced speed in your hydraulic equipment. This drop in performance (especially with an open circuit system) due to restricted fluid flow may have resulted from a clogged filter. As the filter becomes increasingly con-
gested with contaminants, it creates backpressure in the tank line where it’s most nefarious, reducing pressure and flow available to everything upstream.
A clogged hydraulic filter can lead to elevated operating temperatures within the hydraulic system. As the filter restricts the flow of hydraulic fluid, it causes the fluid to work harder to move through the system and often partially through the relief valve. Always remember that any fluid being lost in a hydraulic system before achieving useful work is manifested as pure heat.
One of the primary functions of a hydraulic filter is to prevent contaminants, such as dirt, debris, and metal particles, from entering the system. If the filter is clogged, it cannot effectively trap these impurities when fluid is taking the express bus right through the relief valve. Contaminated hydraulic fluid can cause severe damage to the system’s components, including pumps, valves, and cylinders.
A clogged hydraulic filter can also mani-
It’s easy for the fluid power layperson to misunderstand the fundamentals of filtration, because a clogged filter is actually more efficient at removing both more and finer particles from your hydraulic oil.
fest as an increase in maintenance requirements. If you find yourself constantly cleaning or replacing components within your hydraulic system, it could be a sign that the filter is not functioning correctly. Addressing the filter issue can reduce the overall maintenance needs of your machinery and save you both time and money in the long run. In the worst-case scenario, a severely clogged hydraulic filter can lead to complete system failure. When the filter becomes entirely blocked, hydraulic fluid cannot flow through, causing a sudden shutdown of your equipment. This can result in costly downtime and potential safety risks in specific industrial settings.
Suppose your machine has a filter and no bypass valve, which are more common than you might think. In that case, you must be absolutely sure to use differential pressure indicators to monitor the clogging status of your filter. These indicators can be simple pressure gauges, pop-up indicators or even electronic transducers. Because of the severe repercussions possible without a bypass valve, it can’t be overstated how critical it is to monitor and replace your filter to prevent clogging.
So, as long as you're regularly monitoring your filter's bypass indicator, it's actually beneficial to leave your filter partially loaded rather than arbitrarily changing it out under the assumption that a new filter is better. And the next time the technician at the lube shop pulls out your cabin filter and shows you "how dirty it is," just tell him to put it back because you like it dirty. FPW
These changes can unlock plant-wide air savings, avoid major capital investment, and improve carbon footprint.
Compressed air is one of manufacturing’s largest energy expenses, and most plants run it far above what their machines actually require. By tuning machines that use excess compressed air rather than running at an unnecessary pressure, facilities can safely lower the compressor setpoint and save energy plant wide without capital expenditure.
BY STEVE BAIN INDUSTRY SEGMENT MANAGER, FOOD AND PACKAGING, FESTO
THE OPERATING REALITY IN MOST PLANTS
Most compressor pressure settings are the result of a plant’s history — pressure was raised at some point to solve an immediate production concern and then never brought back down. Without an accurate record of what pressure each machine requires, the higher setpoint remains.
Leakage and unintended air use also increase the system load. A small fitting vibration, a worn seal, or a cabinet cooler left running may seem insignificant, but together they raise the plant’s baseline demand and force the compressor to work harder than the processes truly require.
EXAMPLE: FIVE-MACHINE PACKAGING LINE
Every plant also has a machine or process that is the “highest air consumer” and this is a limiting factor, effectively holding all the machines on a compressor at highest load. Until the highest consumer, the system’s underlying leakage, and unintended consumption are identified and corrected, the compressor cannot be lowered and the plant’s compressed air usage brought down to an optimum level.
TYPICAL COMPRESSED AIR LEAK SOURCES
Five low-cost practices for establishing true air demand at the machine level that help facilities reach maximum energy savings:
1. Eliminate leaks and unintended air use
2. Establish the true minimum pressure for each machine
3. Identify peak-demand events and the limiting machine
4. Reduce demand at the limiting machine
5. Monitor the system to sustain the gains
To illustrate these practices, visualize a five-machine production line consisting of a filler, capper, cartoner, case packer, and palletizer. Each machine in this illustration line uses compressed air differently, and together they represent the kinds of demand patterns found in most plants. The five practices will be used to lower plantwide air usage without major expense or adding new capital equipment.
PRACTICE 1: ELIMINATE LEAKS AND UNINTENDED AIR USE
Leaks and unintended air use raise the baseline pressure the compressor must maintain, increasing energy cost long before the machines even begin to cycle. Much of this loss comes from worn seals,
loose fittings, damaged tubing, or aging piping. Other losses are “designed leaks” that run continuously — vacuum left on during stoppages, cabinet coolers without thermostats, and blowoff air that never shuts off. These losses accumulate across shifts and make it appear that the system requires more pressure than it does.
For example, on the filler in the example five-machine line, a conveyor-side fitting leaked steadily. It was audible with an acoustic wand and immediately confirmed with the imaging tool. Fixing this single leak reduced the filler’s baseline draw, making it easier to lower the machine’s operating pressure in the next step.
Every leak fixed reduces the constant load on the compressor, improves system stability, and creates the headroom needed to safely lower machine and system pressure.
PRACTICE 2: ESTABLISH THE TRUE MINIMUM PRESSURE FOR EACH MACHINE
Machines are often commissioned with regulators set slightly above their required pressure to ensure reliable operation. As
the machine ages, seals, valves, and fittings begin to wear, and air escapes. Small leaks can develop in tubing and connections. Operators often respond by using the regulator to raise pressure to compensate for slowed or inconsistent motion. Over time, these adjustments create an upward creep that makes the machine appear to need more pressure than it truly requires.
To determine the true minimum pressure, a maintenance technician should turn down the regulator gradually until the machine fails to adequately perform its motion. The technician then raises the pressure slightly to establish a stable buffer and records the new setpoint. This reveals the machine’s real requirements at its current state of wear and configuration. The method is simple, safe, and costs nothing, but it must be done methodically so that each axis, gripper, cylinder, or vacuum device is tested under normal cycle conditions.
For example, on the cartoner in the five-
machine line, a technician conducted the pressure test and confirmed that the cartoner can operate reliably at a lower setting, dropping from 80 to 76 psi.
PRACTICE 3: IDENTIFY PEAK-DEMAND EVENTS AND THE LIMITING MACHINE
Lowering machine pressures reduces overall consumption, but it does not reveal which machine creates short-burst, highflow events that momentarily pull down system pressure. These peak-demand events are critical to identify and understand because the compressor must be set high enough to prevent a pressure sag during the heaviest motion on the line.
Peak-demand events may occur when a large-bore cylinder moves a load, when several actuators fire at the same moment, or when a vacuum circuit vents a high volume of air in a single release. A simple fix for an isolated peak event is adding a small reserve tank near the component that creates the momentary drop.
On the cartoner, for example, a reserve tank placed close to the large-bore lift cylinder supplies the burst of air needed for that motion while providing a buffer for the machine pressure. This low-cost step often stabilizes the machine without further changes.
With the peaks removed from the mix, the machine with the highest validated pressure requirement stands out as the
limiting machine — the one that ultimately prevents further reduction of the compressor setpoint.
In the five-machine example, the palletizer now shows up as the highest validated pressure. Its large-bore cylinders consume a high volume of air during every cycle, and that steady requirement, not a momentary peak, establishes the palletizer as the limiting machine.
PRACTICE 4: REDUCE DEMAND AT THE LIMITING MACHINE
Once the limiting machine is identified, the next step is to reduce the amount of air it
requires during normal operation. Excessive demand on a limiting machine often comes from the design engineer, who may intentionally oversize cylinders to guarantee performance. A design with long tubing runs, which use more air, may have been chosen for convenience, and restrictive fittings, which increase pressure drops, may have been specified without consideration for their negative impact on air flow.
Demand on the limiting machine can be reduced by resizing cylinders, shortening tubing runs, replacing quick-disconnects with full-flow fittings, or converting high-volume
pneumatic motions to electric axes. These are targeted updates, not machine redesigns, and they directly reduce the volume of compressed air required for each cycle.
In the five-machine example, the palletizer was identified as the limiting machine. Its lift function was originally handled by a large-bore pneumatic cylinder. Replacing this motion with an electric axis eliminated the cylinder’s high air demand. Once this change was made, the palletizer’s validated pressure requirement dropped, and it was no longer the limiting machine.
The line now had a new limiting machine, the cartoner. Maintenance performed the same targeted adjustments there — shortening a long tubing run and replacing a restrictive fitting — and the cartoner’s validated pressure dropped as well.
After fixing leaks and finding the true operating pressure of the five machines the pressure at the compressor was reduced from 110 to 99. Reducing instances of short high bursts and reducing the limiting machine allowed a second cut from 99 psi to 95 psi, a 14% overall decrease in plant wide air consumption and a 7.5% overall reduction in energy usage according to U.S. Department of Energy guidelines. By preventing pressure creep and maintaining a lower system load, the existing compressor may deliver more years of service, delaying or eliminating the need for a new unit while improving the facility’s overall sustainability profile.
When this process is completed across all five machines, the validated pressures can be compared side-by-side. Once these values are known, the compressor setpoint can be lowered to about 9–10 psi above the highest validated machine pressure, creating an immediate plant-wide savings. On the five-machine line, the com-
pressor was running at 110 psi before leak reduction and individual machine repair. The compressor setpoint has now been reduced to 99 psi, a 10% reduction.
PRACTICE 5: MONITOR THE SYSTEM TO SUSTAIN THE GAINS
Sustaining gains begins with disciplined monitoring. On a regular basis, mainte-
nance personnel record each machine’s validated pressure, noting any trouble shooting adjustments, and verifying that the compressor remains aligned with the current limiting machine. Any upward change without explanation is a signal that a component requires inspection or replacement.
Low-cost red-green pressure indicators mounted directly on regulators or manifolds support this discipline. Green indicates the regulator is at its validated setpoint; red sig nals that the pressure has been increased above the approved value. Because the indicator is on the machine, operators and maintenance personnel recognize the devi ation immediately, and corrective action can be taken immediately. The system will stay optimized, energy use remains at its lowest optimum level, and compressed air becomes a manageable and predictable operating cost. FPW Festo festo.com
Hydraulic Systems Unlocked: Building Efficiency from the Inside Out
Unlock the Full Power of Hydraulics — One Component at a Time
Join us for Hydraulic Systems Unlocked, a six-part webinar series designed for fluid power engineers, OEM designers, and maintenance professionals. Each session explores a key hydraulic component — valves, cylinders, pumps, filtration, hoses — culminating in a final system integration discussion with our experts. Whether you're specifying components, troubleshooting issues, or optimizing system layouts, this series delivers the knowledge and tools to power better hydraulic performance.
Thursday, May 14
Hydraulic Valves: Precision Control for Smarter Systems
Thursday, May 21
Hydraulic Cylinders: The Workhorses of Linear Motion
Thursday, May 28
Pumps & Motors: Power and Performance in Motion
Thursday, June 4
Filtration & Sealing: Contamination Control as a Design Priority
Thursday, June 11
Hose Assemblies: Safe, Flexible Fluid Connections
Thursday, June 18
Hydraulics in Harmony: Integrating Components for Efficient System Design
THE DUST, DIRT AND DEBRIS IN MINING OPERATIONS REQUIRE SPECIALIZED SEALING SYSTEMS TO PREVENT CONTAMINATION AND ELIMINATE THE RISK OF CYLINDER FAILURE.
SealingMiningConsiderations Applications for
Keeping contamination at bay and protecting cylinders in mining applications requires careful selection of hydraulic seals.
By Josh Cosford, Contributing Editor
Let’s just cut to the chase; mining makes for a horrific environment for seals. From incessant contamination to pressure spikes, and from exotic fluids to environmental extremes, pretty much every cause of hydraulic seal failure is well represented in both open-air and underground mining. Mining machines are the heaviest of the heavy-duty, both because of the absolute strength required to extract mountainous volumes of material, but also for their operating conditions, which are some of the harshest on Earth.
Limestone quarries, iron mines, tar sands, and open-pit coal mines all produce a tremendous amount of dust. In many cases, the dust is sized perfectly within the range most damaging to hydraulics — 14 microns or smaller. Of course, such particulate matter is also dangerous to humans, where 85% of occupational deaths occur not from trauma but from occupational disease. So prevalent is mining dust that many jurisdictions require workers to be clean-shaven to prevent particles from penetrating past the tiny gaps in the respirator seal caused by facial hair. A
Such aggressive dust penetration is also a concern for hydraulic machinery, where breather caps are put to task, and cylinder wiper seals are challenged to prevent the ingestion of damaging particles. Drilling, explosions, digging, transportation, crushing, handling, and conveying all contribute to what is essentially taking massive chunks of solid material and reducing it to finer pieces. Those finer pieces make for superior ingredients in concrete, fertilizer, steel, and everything else that makes up the world around us, but act like a lapping compound when allowed to enter a hydraulic system.
Cylinder wipers: the first line of defense
The two primary entry points into the hydraulic system's blood are through the reservoir itself or past the rod wiper and seals in the cylinders. The filter/breather is not limited by sealing technology, but understand that many mining machines may skip the breather altogether for sealed or pressurized systems that avoid inhalation of fine dust and particles. Cylinder rods, on the other hand, may sometimes equip two wiper seals in series to safeguard against drawing dust inward during retraction.
Wipers are durable seals and offered in a surprising number of configurations. For mining, expect only the most reliable combinations, such as a hard rubber or plastic scraper to remove the bulk of the incoming material, followed by an internal wiper made from Buna-N to clean up the remaining fine particles. Expect to see energizers that push the wiper into the rod as it wears, providing longer life while maintaining the interference fit required to wipe contaminants effectively.
Super-duty wipers could be manufactured from bronze or brass, or a combination of polymer and metal. Oil-impregnated bronze with a rubber expander makes a great combination that removes even the most stubborn contamination, while the oil in the bronze lubricates the rod as it wears. Ductile brass is the best gatekeeper, breaking only in the event of a catastrophic event, although it offers the least fine-dust protection due to its lack of compression.
HYDRAULIC SCRAPERS OR WIPERS — LIKE THIS HIGH-METAL SCRAPER FROM TRELLEBORG — SCRAPE DIRT, FOREIGN PARTICLES, CHIPS AND MOISTURE FROM PISTON RODS AS THEY RETRACT INTO THE SYSTEM, PREVENTING CONTAMINATION OF THE HYDRAULIC MEDIUM THAT COULD DAMAGE WEAR RINGS, SEALS AND OTHER COMPONENTS.
Wiper construction runs through the catalog with similar diversity as rod or piston seals; urethane, fluorocarbon, polyester, Buna-Nitrile, and nylon are all available to suit the specific needs of the machine and environment. Without the rod wiper's protection, the ingress of fine dust makes quick work of valve, pump, and motor internals, wearing everything away like fine sandpaper. Before we move on from wiper seals, there is one more type of seal important to mobile machinery that is rarely discussed: the dust seal. Because mining dust gets everywhere, like flour at a bread factory, dust seals are used on cylinder pivot pins to protect the critical internal surfaces and prevent grease from turning into pumice hand soap. Cylinder pins are a common wear location when not properly maintained and lubricated, so steel-backed rubber dust seals keep grease in and dust out, ensuring reliable operation of everything from dump trucks to roof supports.
High pressures and extreme environments
Although many mining hydraulic systems don’t operate above standard pressure settings seen in comparable technologies, shock loads and their resulting pressure spikes are a real concern in mining. You'll
notice mining machinery is comically large, such as ultra class haul trucks that stand many stories tall. Their height and wheel size make their beds appear relatively small compared to the same ratio of your wheelbarrow, but don't be fooled — these machines can haul hundreds of tons of material while travelling over 40 mph (having thousands of horsepower helps).
The strength of mining machinery isn't just a reflection of their scale, but also of the abuse they endure in their daily roles. Consider that an open-pit mine shovel (a form of excavator) can bomb single loads over 90 tons, impacting the dump truck like a sledgehammer carnival game. Although lowered dump beds use physical stops to prevent damage to hydraulic cylinders, they must be designed to withstand such loads regardless. The same concerns apply to underground mine roof supports, which use robust hydraulic cylinders to create a temporary roof that must bear the weight of a cave-in. Those loads create pressure spikes, and seals are the first place a pressure spike attacks.
Cylinders perform well when equipped with specialized seals on top of traditional, robust designs. Buffer seals added to the rod gland help absorb some initial shock load, and then harder polyurethane primary seals make a great choice for
Solutions Under Pressure
strength and longevity. Even in static locations, such as barrel end seals or rod gland seals, backup rings are used to help prevent extrusion, while lighter-duty applications make do with simple O-rings.
Such heavy-duty applications are also highly dependent on precise seal pocket geometry. Sometimes holding tight tolerances is difficult when machining a 40 in. bore, multi-stage cylinder, so don't expect to repair these cylinders at your local hose shop. With ultra-small extrusion gaps, even high-pressure spikes cannot push synthetic rubber out through the microscopic clearances these cylinders are machined with.
Premium materials a must
Mining machines, depending on their purpose and location, may generate tens of thousands of dollars per hour in revenue,
need to worry about trans fats here.
HNBR offers superior heat resistance compared to standard Buna Nitrile, especially when cycles span a wide range of cooling and heating, where it's better able to resist hardening. When standard Buna Nitrile experiences frigid temperatures and then rapid warm-ups to operating conditions, repeated cycles can lead to the seal becoming brittle over time, so HNBR provides superior resistance to this type of degradation. Additionally, HNBR offers superior abrasion resistance, providing a more reliable solution even in temperate climates.
Polyurethane is already extremely common in high-pressure hydraulics, but you'd be shocked to discover the vast range of quality that thermoplastic polyurethanes now range. Some advanced, proprietary urethane chemistries further increase resis-
ature resistance. However, be careful with extreme pressure; Viton requires extremely precise pocket dimensions to prevent extrusion, as it is quite soft. If your fluids are especially aggressive, such as polyol esters, also consider Viton’s brother, FFKM, which is essentially chemically bulletproof.
Speaking of bulletproof, the rise of PTFE (Teflon) based composites has accelerated in recent years. Because PTFE is a plastic, it does not mold well to the shape of its seal groove, so leakage is a potential downside. However, with spring or rubber energizers to help push the PTFE into its cavity with more vigor, it's better able to operate while passing less fluid.
Some manufacturers may acknowledge and accept some leakage for what is possibly the most durable material available for hydraulic cylinders, and I mean that despite the most pressure, heat, and chemical
so downtime must be mitigated at all costs. Quality and reliability are the main drivers behind any hydraulic machine, especially when you factor in the remote locations many mines operate at. Then, when you add the complexity of deep mines and enclosed spaces, the ability to deliver replacement seals to their repair location can be difficult at best, so mine operators expect only the most premium synthetic rubber compounds.
You’re probably wondering what makes rubber “premium,” so let’s just discuss how not everyone has the same product offering, without naming any brands or getting too specific. If you’re going to use Nitrile Butadiene Rubber, be sure it’s hydrogenated. Hydrogenation adds hydrogen to unsaturated carbon bonds, and despite the same effect it has on food oils, you don’t
tance to abrasive wear, extending seal life even in the face of fine mining dust. These advanced compounds use stabilized chemistries that resist hydrolysis and swelling from extended water exposure, which is quite common in mining because of the prominence of fire-resistant waterand glycol-based fluids. Combine these features with improved shear strength and reduced friction, and you'll find across-theboard improvements with only one downside: cost.
Of course, other technologies complement the fire-resistant, water-based fluids required for underground mining, which prevent hose failures or leaks from turning into explosion-inducing flame throwers. FKM (Viton) is the go-to technology that works great with water and other exotic fluids while also offering extreme temper-
aggression you can throw at it. When combined with fillers such as glass, bronze, and carbon, the PTFE seal also exhibits excellent wear resistance even under high velocity and load.
Mining in general is not for the faint of heart, and everything from mine hoists to shovel buckets is supersized to meet the demand that our world places upon the extraction of natural resources. Temperature extremes, elevated working and spike pressures, and one of the dirtiest operating environments make sealing a challenge. However, modern materials, geometries, and installation techniques have allowed mining to enjoy one of the most productive and efficient industries on Earth. FPW
JPREMIUM MATERIALS ARE CRUCIAL TO SEALING SYSTEMS USED IN MINING OPERATIONS, AS THEY MUST BE ABLE TO WITHSTAND EXTREME TEMPERATURES, EXOTIC FLUIDS, AND HIGH PRESSURES.
Stackable solenoid valves for compressed air control
Spartan Scientific spartanscientific.com
Two-speed axial piston motor
BMV Integrated Drive Motor is a two-speed axial piston motor with integrated planetary reduction gearbox. Previously offered only in select markets, it is designed for dual-path tracked machinery such as compact track loaders. It comes in two frame sizes and four displacements: 28, 32, 41, and 51 cc. It offers imperial and metric port configurations, with optional features such as a loop flushing valve and a PLUS+1 compliant speed sensor. Its compact, lightweight package supports installation, removal and gear oil changes.
Machine guarding hydraulic lockout valve
H L-O-X series hydraulic lockout valves for machine guarding applications block the flow of hydraulic fluid to stop cylinder motions. This valve safely bleeds pump flow and downstream pressure to tank through its own independent, full-flow exhaust lines. A manually operated handle can accept a lock or hasp to prevent the reapplication of pressure buildup. These valves are rated to 6,000 psi (414 bar) and are available in 1/2, 3/4, and 1-1/4 in. port sizes with flow rates of 20, 35, and 50 gpm, respectively. Each valve is made of carbon steel and includes Delrin and nitrile rubber (Buna-N) seals.
Series 1090 and series 1590 stackable solenoid valve platforms for compressed-air control in compact electro-pneumatic systems are intended for OEMs and system integrators where space constraints are a factor. The Series 1090 is a 10 mm-wide stackable valve rated for low-power switching and up to 50 million cycles in clean, dry air applications. It is aimed at analytical instrumentation, medical devices and automation systems with limited panel space. The Series 1590 is a 15-mm-wide, stackable platform with orifice options up to 1.5 mm and pressure capability up to 145 psi. It has an IP65 rating for environmental protection in humid or dirty conditions.
P.TRACE industrial pressure transducer is designed for applications requiring accurate pressure measurement and fast response. Compact stainless steel unit measures liquid, gas or viscous media from 0 to 8,700 psi using a ceramic sensing element. It can be used to monitor pressure in hydraulic circuits, verify coolant supply in thermal processes and measure process pressure in industrial plants. The 33-mm long stainless steel housing connects via an M12 4-pole plug connection. It has one analog output, 0.5% FSO accuracy and an MTTF of 2,236 years in continuous operation.
