From tiny seals and filters to powerful hydraulic systems, new advancements are improving the safety, reliability and performance of heavy-duty vehicles. These trending technologies solve problems such as efficiency gains for the designer all the way to productivity gains for the operators. Parker is applying decades of engineering expertise to work with engineering teams to solve complex challenges in heavy-duty vehicle applications. As we partner with vehicle OEMs to address the ever-changing needs of end users, examples of our customer-driven solutions include:

Parker's EO-3 Fittings are customized for each application. They offer reliable tube and hose line connections thanks to unique features such as:

• Indicator rings that provide visual confirmation of a proper connection.
• Tapered threads to make installation easier with less canting.
• Octagonal nuts for better access.

Compact Spiral Hose can be bent more tightly and with less effort than traditional hoses. At the same time, it also achieves greater strength and a longer service life. Its outside diameter is 30 percent smaller than other hoses, so it is easier to install, and uses 40 percent less material than a traditional hose.

The Parker Tracking System (PTS) works with special barcoded labels and RFID tags that make it easier for companies to track and maintain their Parker components. With the PTS technology, customers can track the type and age of their hoses, their manufacturing information, and when they need to be replaced. This makes it easier to have the right parts at the right time and eliminate unnecessary and costly downtime.

SNAPP filters are designed for small engines of up to 140 horsepower (hp) or with fuel flows of up to 26 gallons per hour (gph). They offer a tool-free snap-in installation process, utilize a self-venting drain, and have a clear bowl for easy inspection. SNAPP filters are even designed to be leak free.

Parker has recently developed three exciting innovations in hydraulic cylinders:

• Intellinder - Intellinder hydraulic cylinders are designed with an absolute position sensor that reports the exact position of the sensor -- rather than how much it has moved -- back to the controller. This offers greater accuracy and consistency, without the need for constant recalibration.
• Global Shield Coating Technology - Parker's Global Shield coating provides up to seven times the corrosion resistance of a traditional nitride or chrome coating, reducing the total cost of ownership.
• Lightraulics Composite Hydraulics - Capable of withstanding up to 380 bar of pressure, or 700 bar in a custom design, Lightraulics composite cylinders offer the strength of steel with extreme lightness. Up to 60 percent weight savings are within reach with a system that leverages Lightraulics technology, while composites also bring the benefit of greater corrosion resistance and faster acceleration for maximum productivity.

Parker’s P1/PD medium pressure axial piston pumps utilize electronic control systems to optimize performance. With the ability to work with or without an ECU and to support whole-vehicle CANbus systems, the P1/PD series offers a broad range of controls, including load sensing capabilities.

Our new VP120 load-sense directional control valves leverage flow-sharing technology to help mitigate the problems caused by pump over-demands. They are also designed to be modular so that functionality can be added or removed as needed, and support both load-sensing and load-sense pressure compensation.

Capable of controlling both AC induction and AC permanent magnet electric motors, the MB2 mobile control is designed for both on- and off-road applications and is ideal for both electric and hybrid-electric vehicle platforms. It can handle up to 800 volts of direct current (VDC) and 120 kilowatts (kW) of power, and supports digital, analog and CANbus communication.

Featuring an internal permanent magnet design, GVM traction motors come in two different sizes and offer up to 900 newton meters (Nm) of peak torque. We design them for full-electric and hybrid drive trains for a wide range of vehicle platforms. The GVM series is distinguished by its ability to provide its peak performance at power levels ranging from 15 to 210 kW.

Parker's unique Resilon 4300 polyurethane offers better seal design and better material performance than seals made of other materials. Resilon 4300 is stronger and offers greater resistance than other polyurethanes and is able to withstand extreme temperatures both high and low.

Air duct seals coated with TriCom-HT have lower oxidation rates and much longer service lives than traditional seals. This electro-deposited coating combines a cobalt-nickel alloy with chromium carbide for performance at peak temperatures of 1550°F (843°C), while also offering lubricity and increased hardness.

Other related articles on heavy-duty vehicle design include:

Electronic Control Systems for Heavy-Duty Vehicle Implements

Natural Gas Engines for Heavy-Duty Applications

Optimized Fluid Conveyance Systems for Heavy-Duty Vehicle Chassis

Designing a Heavy-Duty Construction Vehicle Cab

Hydraulic Technologies and Key Markets

After 30 years of experience in manufacturing attachments for machines such as back hoes and graders for the earth moving industry, as well as pole drills, snow blowers and flail movers for the municipal industry, the Barcelona-based engineering company Euroimplementos decided to widen their range to include complete machines. Withexperience also in manufacturing the actual breaker head, a demolition machine was the first one out.

The team was operating on a very tight time schedule, and there was no time for mistakes. The demolition machine on the drawing board, an RDC 22.20, needed to out-perform existing machines on the market by providing longer range, higher capacity and a much more “competent” chassis with dual dozer blades and extendable tracks, as well as extendable blades for increased stability.

Based on earlier experience working with Euroimplementos, along with the significant business opportunity the project presented, Parker’s Spanish mobile team headed by Felix Chacon engaged in in system discussions.

The first challenge was that all of the chassis functions needing a rather extensive rotary distributor, which is expensive, space-consuming and complex. This was solved by simply placing a complete valve with an IQAN expansion unit on the chassis frame, thereby reducing the number of hydraulic lines to 4 and the electric lines to the CAN-bus connections for the IQAN system.

For the chassis, a Parker 6-bank P70CP valve was chosen, as the need for multifunction operation was rather limited and so was the space available. For the superstructure a Parker 7-bank L90LS was chosen, providing refinements in spool selection, feeding reducers and optimized controllability.

The machine was to be powered by a 22 kW electric motor with direct coupled pumps, one PV+ 45 cc for the main functions with a piggy-back PGP 31 cc for the kidney functions -cooling and filtration. Considering the rather awkward operating environments, a large kidney filter and a well dimensioned tank breather filter were selected.

To hook it all up, the Genuine Parker Parts (GPP) team was called in to assemble all hoses, connectors and fittings.

“We were extremely impressed with the competence and deep application knowledge presented by the Parker team even on components and topics not in their normal range. They were able to provide valuable advice on a range of important topics, including cooler size, tank size and, equally important, tank design, to mention a few. The IQAN system, with its radio control module, turned out to be as good as they claimed it to be, and with the support and training from Parker, we managed to get the machine ready in time for our target launch date” ~ Sr. Ramón García of Euroimplementos.

For more information, please contact Felix Chacon at Parker Sales Company Spain.

Learn more about Parker's Hydraulic Technology in this video

Other related articles on heavy-duty vehicle design:

Top Innovative Products and Systems for Heavy-Duty Vehicles

Electronic Control Systems for Heavy-Duty Vehicle Implements

Natural Gas Engines for Heavy-Duty Applications

Optimized Fluid Conveyance Systems for Heavy-Duty Vehicle Chassis

Designing a Heavy-Duty Construction Vehicle Cab

The co-located IFPE and CONEXPO-CONAGG show, which occurs every three years in Las Vegas, Nevada, is among the largest tradeshows in the world. This year the international expo attracted nearly 130,000 attendees, and manufacturers and suppliers gathered to demonstrate the latest technologies in the construction industry.

Parker’s booth at IFPE 2014 featured innovative products and systems to improve the efficiency and performance of heavy-duty construction vehicles. While a variety of solutions from Parker’s different groups demonstrated the company’s broad range of capabilities, the booth was organized into four primary areas in which Parker products and systems can be found on heavy-duty vehicles: the cab, implement, engine and chassis.

The cab display at Parker’s IFPE booth highlighted the ways in which we are partnering with manufacturers to improve the safety, comfort and productivity of heavy-duty vehicle operators. Visitors were able to learn about Parker’s new display modules, GPS telematics systems, ergonomic joysticks and other solutions helping to improve heavy-duty vehicle cab design.

As fuel costs rise and emissions standards become increasingly stringent, it is becoming increasingly important to maximize the efficiency of heavy-duty vehicle engines.  Parker’s engine display at IFPE demonstrated how, by providing a range of hoses, filters, PTOs and other products, Parker partners with engine manufacturers to reduce the fuel consumption and emissions of heavy-duty vehicles without impacting performance.

A hydraulic system is only as capable as the fluid conveyance technologies it consists of, so among the most important components of any hydraulic system are the seals, wipers and O-rings that contain the fluid. Parker experts were on hand at the chassis display at IFPE to explain to attendees that, given the extreme temperatures and pressures the systems experience, utilizing the right kind of materials on a heavy-duty vehicle chassis can make the difference between years of successful operation and frequent failures and breakdowns.

Recent advancements in heavy-duty implement design have been characterized by the transition from mechanical to electronic implement control systems. By combining heavy-duty hydraulic cylinders and pumps with precise electronic sensors, Parker offers vehicle operators greater responsiveness, finer control, increased efficiency and an unparalleled level of ruggedness and reliability.

Overall, Parker’s booth at IFPE 2014 was prominently located near the entrance of the Las Vegas Convention Center and was well-attended throughout the week.

Participation at the show was mutually beneficial for Parker and those who visited our booth; Parker experts were able to educate attendees how our products help to increase heavy-duty vehicle efficiency and maximize performance, while also gaining a unique perspective from customers on the latest trends in the construction industry.

As fuel costs continue to rise and vehicle emissions standards grow increasingly stringent, both municipal and private fleet managers must find new ways to contain operating costs by increasing the efficiency of their operations.

It is also evident that virtually every company serving the waste collection and processing industry is committed to their obligation to act as environmental stewards throughout their operations and in their products.

Parker shares this focus and is partnering with its customers to develop and implement new products and systems which will help the waste industry achieve their environmental and sustainability goals.

Parker’s Global Shield Coating is a new exclusive plating technology available from Parker. When applied to cylinders used throughout the waste industry, whether on refuse collection vehicles or industrial recycling or shredding facilities, the Global Shield coating provides extended cylinder life in abusive environments without the negative environmental impact that occurs with hexavalent chromed solutions.

Global Shield coating provides up to eight times the corrosion resistance of a traditional nitride or chrome coating, reducing the total cost of ownership.

Parker’s Intelligent Flow Control (IFC) system architecture is applicable to both mobile and industrial motion and control applications. IFC utilizes electronic displacement controlled pumps, available from Parker, in conjunction with multiple valve designs to provide significantly faster system response to improve productivity, often by 15-20%, while reducing parasitic losses experienced in open center systems or in the form of margin pressure savings in load-sense systems.

RunWise is an advanced series hybrid drive system with brake energy recovery. The brake energy recovery system converts the vehicle’s kinetic energy into stored energy by compressing nitrogen gas in a storage device called an accumulator. This stored energy is then released during acceleration to reduce the energy required from the engine to propel the vehicle.

Through the series drivetrain architecture, the engine can be operated at speeds independent of vehicle speed. As a result, the engine always operates at the ideal spot for any power level demanded by the vehicle operator, which can be a limitation of a conventional transmission.

By reducing energy demand, RunWise reduces fuel consumption, regardless of fuel source, by 35 to 50 percent, depending on route density and operating conditions. A truck equipped with RunWise hydraulic hybrid system can consume 4,300 gallons less fuel per year than a truck utilizing a standard transmission. This equates to an average annual reduction in CO2 emissions of 48 tons per year, equivalent to removing 10 midsized cars from the road or planting 1,100 trees and letting them grow for 10 years.

In addition to reducing fuel consumption and emissions, Parker’s brake energy recovery technology lengthens the brake replacement cycle to one or two brake jobs throughout the life of the truck (depending on duty cycle), dramatically reducing maintenance costs as well as the disbursement of brake dust into the atmosphere. By improving acceleration and braking, RunWise can also reduce collection times by 1-2 hours.

Read a white paper which explains how RunWise is helping to reduce fuel consumption and emissions in refuse applications. 

Parker is committed to maintaining its leadership in advancing motion and control components, systems and technologies with focus on improving its own environmental footprints as well as assisting its customers and served markets in achieving their environmental goals.

Hydraulic Hybrid Fleet Approaches One Million Miles of Operation

Series Hybrid Vehicle System Design

Top Innovative Products and Systems for Heavy-Duty Vehicles

Series Hybrid Vehicle System Design

Parker has entered into a partnership with Big Truck Rental to offer refuse trucks equipped with the RunWise Advanced Series Hybrid Drive System for rent.

RunWise is the first hybrid technology widely available in rental markets.

“Our partnership with Big Truck Rental gives municipalities and fleet managers the opportunity to test and experience the significant savings and environmental benefits of the RunWise-equipped trucks and learn how their fleets can benefit from hybrid technology."

Shane Terblanche, general manager, hybrid drive systems at Parker Hannifin.

The Autocar E3 equipped with RunWise technology is now available through Big Truck Rental to all municipalities and waste management companies on a rent-to-own basis. RunWise global commercial truck customers have already surpassed one million miles of operation with reduced fuel consumption by up to 50 percent and reduced maintenance costs.

“Our customers have been asking for a technology that can reduce operating costs while providing an environmental benefit. Parker RunWise is the premier cost-reducing technology on the commercial market and we are excited to address our customers’ needs.”

Scott Dols, president and CEO of Big Truck Rental.

Parker Hannifin and Big Truck Rental will display a refuse truck at the WasteExpo in Atlanta, Ga. from April 29 to May 1. Both companies will also be exhibiting at the ACT Expo in Long Beach, Calif. from May 5 to May 8.

For more information, visit Parker's Hydraulic Hybrid website and watch several of the latest videos of customer testimonials, including this one:

Related Content:

Reducing Environmental Impact in the Waste Industry

Hydraulic Hybrid Fleet Approaches One Million Miles of Operation 

According to a study published by Mobil Oil’s commercial marketing department, one leak at a rate of a drop every five seconds amounts to 80 gallons of hydraulic fluid per year. That $400 may not seem significant, compared to the cost to repair, but once you factor in the estimated $7.00 that will need to be spent on cleanup per every dollar spent on the lost oil, you can add another $2,800 to the financial impact, for a total of $3,200 for one drop, every five seconds, from one leak point. How many leaks will you tolerate with this in mind?

Here are some other costs to consider:

Direct Expenses

• Cost of personnel and their expenses during cleanup
• Cost of clean-up contractors if necessary
• Regulatory fines/penalties due to the spill
• Cost of oil lost
• Cost of damaged equipment, infrastructure
• Natural resource damages (if applicable)
• Cost of spill control supplies, equipment
• Cost of claims by third parties

Indirect Expenses

• Loss in productivity
• Increased attention from regulators
• Need for more training, inspections, planning
• Damage to business reputation
• Higher insurance premiums
• Increased space required to store spill control supplies

One of the most vital systems that you need to consider in extending the life of a machine is your hydraulic system. In creating a maintenance plan for your fleet’s hydraulic systems, the manufacturer’s suggested service intervals are just one input that you should consider. Your original equipment manufacturer (OEM) doesn’t consider the variables of operator skill, climate, environment or a host of other conditions in the development of their preventive maintenance (PM) guidelines.

A successful PM program relies on monitoring a variety of inputs, including those of the operator, to establish a schedule that best meets the requirements of the conditions in which the equipment operates. In order to prevent failure and still obtain the maximum value from your asset, your PM should be routine and as unobtrusive as possible to the productivity of the machine.

Before discussing an approach to PM programs for hydraulic systems, maybe it’s best to take a moment to talk about what types of failures can occur. In general, failures come in three forms.

Degradation failure.  This type of hydraulic system failure most often associated with machine age or use. Degradation failure is the gradual deterioration in the performance of a component caused by wear or the effect of induced contamination, resulting in the need for repair or replacement.

Transient failure. Another type of failure is referred to as transient failure. As the name suggests, symptoms of this type of failure may come and go, although generally, the consequences are much longer lived. An example of a transient failure might be particles that momentarily interfere with the function of a component. The particles lodge in a critical clearance between matching parts, only to be washed away during the next operation cycle. Presence of transient failures are often first noticed by equipment operators (“the machine felt a little hesitant”), which underscores the importance of including their input in any hydraulic PM program. Operators should be encouraged to report immediately any aberrant machine performance to their service superintendent because these failures tend to be symptomatic of larger issues.

Catastrophic failure. Failure to address transient failure issues over extended periods of time can result in catastrophic failure. This type of failure usually occurs “without warning,” though prior warnings most likely went unheeded or unreported. This type of failure is generally the most costly to repair, and costs associated with them can far exceed the time, labor and parts required.

In an ideal world, developing a PM program that addresses the causes of degradation failure would effectively mitigate the other types of failure. But this is not the reality we live in. The reality is that the equipment that you manage probably varies in age, and you may not be the first or only owner. Therefore, you don’t know how well it was maintained, or how often it was serviced. The other truth is that there are some components of a hydraulic system that just have a limited life span. These so-called “wear components” include hose assemblies, O-rings and seals.

Given these factors, a well-designed Preventive Maintenance (PM) program should align with all three potential failure types.

Learn more about Parker's Hydraulic Technologies in this video:

This article is Part 1 of a 2 part series contributed by Bogdan Kozul, technical training manager and Margaret Wilburn, marketing services coordinator for  Parker Hannifin Corp.’s hydraulic product group.

Other content related to hydraulics and maintenance:

Reduce Failure of Hydraulic Systems with Preventive Maintenance

How to Extend the Life of Your Surface Mining Hose

Reliability Centered Maintenance Reduces Costly Downtime in Oil & Gas Applications

A Dollars and Sense Approach to Preventing Hydraulic Oil Leaks

Essential Factors for Selecting Hydraulic Cylinders for Tough Operating Environments in Aluminium Processing

The first line of defense in reducing failure of a hydraulic system is to incorporate contamination measurement and control protocols as an integral element of your Preventive Maintenance (PM) program. This is not to suggest that your shop has to be a clean room; the goal is to recognize the sources of contamination and ways to reduce them.

Contamination, as with failures, comes in many forms, the most common of which include the following:

• Built-in contamination from the manufacturing and assembly processes includes debris, weld spatters, casting sand, paint, pipe sealant or fibers from cleaning rags.
• Natural contamination is the particulate matter that’s present in hydraulic fluid before filtration. Production, packaging, transport and distribution may all be sources of this type of contamination. Pre-filtering hydraulic fluid before adding it to your machines' sump is highly recommend.  Without pre-filtration, you risk introducing contaminants to your hydraulic system.  Unless you take the (highly recommended) step of pre-filtering your hydraulic fluid before adding it to your machines’ sump, you risk introducing contaminants to your hydraulic system.
• Ingressed contamination is introduced via air breathers, cylinder rod seals, wiper seals, component seals or poorly fitted covers, to name a few potential paths. These contaminants can’t be 100 percent avoided, but there are aftermarket solutions to reducing them.
• Generated contamination is the result of particles generating bigger particles. Abrasion, cavitation, corrosion, erosion and fatigue resulting from contact between moving parts are all examples of the effects of this type of contamination.
• Catalytic contamination refers to the presence of non-solid contaminants, chiefly water, air or heat, that react with the other particulates present in the hydraulic fluid. For example, the combination of water and wear elements such as iron or copper can result in a catalytic effect that is significantly greater than the individual contaminants.

Regardless of the source, these contaminants can rarely be seen by the naked eye. As with engine oil, the key to identifying contaminants that may be present in your system lies with routine fluid sampling and analysis.

Fluid analysis identifies contaminants at a chemical level. The presence of certain contaminants can be a predictor of the source, and therefore, they can be an indicator of an approach to resolving the issue. Chemical analysis of hydraulic fluid is best left to a lab, and many offer this service at a relatively low cost.

A fluid’s particle count is a clear indicator of the severity of contamination or potential to cause further damage. There are many commercially available particle counters on the market that make particulate measurement a cost-effective endeavor.

More frequent drain and change intervals is one approach to contamination reduction, but one that will probably have a negative impact on machine productivity. Close attention to the type and quality of the filters that you employ at various points in your hydraulic system is likely going to be more cost effective.

Filters that may seem comparable can also vary in the type of media used, manufacturing process and other more subtle differences. Ensure that the filters you use meet or exceed the acceptable levels for particulate filtration and flow rate for the filter location within the system and the equipment that you are managing. Refer to OEM guidelines for specifications.

Warning: all filters are not created equal. Filters vary greatly in two important factors

• Size of the particle they are intended to filter
• Flow rate through which media (hydraulic fluid, in this case) passes through the filter

Even with a rock-solid contamination control program in place, contamination will inevitably migrate into your hydraulic system to the point where its effects become noticed by your operators or technicians. Sticking valves, machine hesitation or lag, or general sloppiness can all be symptoms of a potential problem. Since these problems can come and go, having the tools and processes in place to identify and quantify these hard-to-replicate situations is something that is best addressed by incorporating a system of diagnostic tools into your PM toolbox.

Diagnostic tools can be as simple as a plug-and-play digital pressure recorder that measures pressure spikes or drops experienced during a shift or over an extended period of time. They can be as complex as those that measure a variety of key hydraulic system data points simultaneously, including pressure, temperature, flow and rotational rate with recorded data exported into the data analysis software of your choice. This data can be compared with OEM specifications to identify potential issues or to prioritize additional maintenance tasks before they lead to catastrophic failure.

The application of any data-gathering device will require a bit of forethought, including the installation of quick-connect test points at key locations within a hydraulic system. Once installed, these test points provide easy access to the information that can be indicative of a greater problem and will dictate your approach to resolving it.

All of the detail provided by your contamination control and diagnostic processes will be extremely valuable in showing a potential buyer that you’ve taken seriously the care of your equipment and have the documentation to back it up. A folder full of documents that give evidence of everything you’ve done to keep a machine in top condition can have a substantial effect on the selling price or trade-in value of a machine that could outweigh the investment you made in its care.

The inspection of a machine’s hydraulic system as part of every operator’s daily routine ensures that any issue that needs to be addressed is caught as early as possible. Inspect every machine, every day, the same way. This inspection checklist should ideally be performed at the beginning and end of every shift, and submitted to the shop superintendent for review. Your team should determine the level of detail for these inspections, but they should be consistent from machine to machine and rigorously adhered to.

Operators should make special note of any transient failure issues they experienced during their shift, and should inspect their machine for the following early warning signs of catastrophic failure. Hydraulic systems are potentially hazardous. Service required should be performed by a technician specifically trained in hydraulic system plumbing and maintenance.

Hose assemblies. Visually inspect hoses for the following conditions, any of which indicate the need for immediate replacement: fitting slippage on hose; damaged, cracked, cut or abraded cover (any reinforcement exposed); hard, stiff, heat-cracked or charred hose; cracked, damaged or badly corroded fittings; leaks at fitting or in hose; kinked, crushed, flattened or twisted hose; and blistered, soft, degraded or loose cover.

Hard lines. Visually inspect hard lines and tubing for signs of fatigue, cracking, kinking and leaks either in the length of the tubing or at connection points.

Cylinders/actuators. Make note of any scoring, pitting or accumulated hydraulic fluid on cylinders or actuators. Whenever there is a suspicion that metal particles may be in the system, it should be reported, because the oil must be drained, the entire system flushed clean, and any filter screens thoroughly cleaned or replaced. Packing, wipers and bushings are considered wear components and should be replaced based on manufacturer’s specification or when signs of wear are apparent.

Filters. Make sure that you check the filters in all locations of your hydraulic system. Many filters have visual indicators that show that they are operating correctly. Report any filters that indicate a clog or that have gone into bypass mode. These indicate the need for immediate filter replacement, and possibly a complete flush of the system and fluid replacement. (See accompanying illustration for filter locations.)

Sumps. Inspect the tank and check for any water or moisture by taking a sample from the bottom of the tank (oil floats on water). As discussed earlier, the presence of water in the hydraulic circuit can cause serious damage to hydraulic components because of the way it reacts with other contaminants. If found, water must be purged at regular intervals. Note any accumulation of varnish buildup, as this may cause sticking or filter clogging and may indicate the need for fluid replacement.

Odors. Have operators/inspectors make note of any strong or unpleasant odors, especially heat-related odors, which can be indicators that your system is operating at unsafe temperatures, that fluids may be leaking onto high-temperature surfaces, or that fluid viscosity has been compromised.

Zero tolerance for leaks. Remember, any place that hydraulic fluid can get out, potential contaminants can get in, including particulate and catalytic contaminants that can have a significant impact on the life of a hydraulic system. Leaks in your hydraulic system aren’t just an annoyance; they are a financial burden to your business. Setting aside the fact that the location of a leak is a potential access point for contamination at best, and at worst, a pre-cursor of a catastrophic failure, there is a purely financial motive for a zero tolerance for leaks policy.

In 1995, Parker became one of the first to successfully market the concept of a portable particle counter, the PLC-2000.  Since then, Parker has grown into the industry leader for condition monitoring products.  A variety of both proven and leading-edge products are now available for applications in both the industrial and mobile marketplace. Consider speaking with one of our engineers about a condition monitoring program, or review available condition monitoring equipment on our website.

• Certification of fluid cleanliness levels
• Early warning tool to help prevent catastrophic failures in critical systems
• Immediate results with laboratory accuracy
• To comply with customer cleanliness requirements and specifications
• New equipment warranty compliance
• New oil cleanliness testing
• Identification of a fluid's saturation point and/or water content
• Continuous monitoring for water contamination

Download Parker's Handbook for Hydraulic Filtration - Fluid Cleanliness Standards

This article is part 2 of a 2 part series and was contributed by Bogdan Kozul, technical training manager and Margaret Wilburn, group marketing communications manager for Parker Hannifin Corp.’s hydraulic product group

Other posts related to maintenance:

Reliability Centered Maintenance Reduces Costly Downtime in Oil & Gas Applications

A Dollars and Sense Approach to Preventing Hydraulic Oil Leaks

Best Practices for Hydraulic System Maintenance

Parker has partnered with Autocar, Heil and Republic Services to develop and validate a proof of concept Compressed Natural Gas (CNG) fueled refuse truck equipped with the RunWise Advanced Series Hybrid Drive System. The demonstration was conducted in Chula Vista, California over one month on a collection route typically served by a traditional CNG truck.

RunWise is an advanced series hybrid drive system with brake energy recovery. The brake energy recovery system converts the vehicle’s kinetic energy into stored energy by compressing nitrogen gas in a storage device called an accumulator. This stored energy is then released during acceleration to reduce the energy required from the engine to propel the vehicle.

As a vehicle fuel source, natural gas provides comparable amounts of power and acceleration to diesel, while producing lower levels of emissions and particulates, all at a significantly lower cost.

RunWise improves upon the typical gains achieved by using natural gas as a fuel source, making these refuse trucks the cleanest environmental solution on the road today. As many municipalities and fleet operators look to convert to CNG, the RunWise system is attractive to those who are under pressure to meet reduced emissions mandates.

“We are pleased with the initial results of the CNG powered RunWise refuse trucks. Test data shows that the RunWise system is delivering up to 20 percent incremental fuel savings over traditional CNG trucks and a 10% improvement in productivity, and we can anticipate that reduced brake wear and routine maintenance requirements will also contribute to the value of these clean energy vehicles.”

- Shane Terblanche, General Manager, Hybrid Drive Systems Division

Parker will continue to develop this technology with its industry partners to commercialize a CNG option for its RunWise Advanced Series Hybrid Drive System.

With a million miles of operation and 99 percent uptime, Parker’s RunWise technology has proven effective in consistently providing significant reductions in fuel consumption and emissions resulting in numerous repeat orders, and drivers who appreciate the responsiveness and reduced noise. RunWise is unmatched in its ability to reduce emissions and allows for smooth transitions between stopping and accelerating that result in quieter garbage pick-ups for neighborhood residents.

Click here to learn more about the CNG fueled RunWise refuse truck, and visit the links below to learn more about hydraulic hybrid technology. 

Hybrid Technology Now Available in the Rent-to-Own Market

Reducing Environmental Impact in the Waste Industry

Hydraulic Hybrid Fleet Approaches One Million Miles of Operation

In power generation, hydraulic cylinders are used in hydroelectric-dam settings for gate actuation and governor control. Standard positioning technologies rely on magnetostrictive sensors, variable resistance sensors (string pots) and laser gauges. These all have limitations, including short strokes, dead zones, calibration needs, water ingression, temperature range restrictions, interference from contaminants, annoying electrical noise and time-consuming removal and repair.

These problems all add inefficiencies to dam operation, which increases operational cost.

Now, however, a new “smart” cylinder from Parker called IntellinderTM can eliminate these problems and streamline operations.

Designed for hydro-electric gate actuation and governor control, Intellinder integrates a highly engineered sensor into the hydraulic cylinder. Advantages include:

• installation is virtually plug-and-play
• steel and stainless construction available as NFPA tie rod or round line design
• exterior mount, non-pressurized, non-contacting sensor that is easy to replace
• extreme operating temperature rating (-40 to 220f)
• universal across a wide range of cylinder bore and rod diameters, with stroke lengths up to 20 feet
• sensor remains impervious to electronic noise
• CAN communication to signal conditioning electronics allow long cable runs
• up to eight Intellinder cylinders can be connected to a single bus, offering reduced installation and commissioning costs

The Intellinder sensor signals absolute positioning, rather than position relative to the starting location and end point of the rod. Position-identifying bar codes are marked on the rod so its position is communicated continually and directly to the controller. Position report occurs at power-on and does not require calibration. The sensor even enables monitoring in double-rodded cylinder applications, allowing customer utilization of both rod ends. True redundancy is achieved by simply adding multiple, non-contacting reader sensors to the cylinder.  

The Intellinder absolute position sensor is designed to sustain performance in harsh environments, including hydroelectric plant and dam environments, where applications expose the cylinder to vibration, dust, gravel, corrosives, chemicals, axial load and side load. Long cable runs up to 300 feet from the farthest cylinder to the output module can be obtained. Intellinder feedback devices can be networked together, just like networking computers together over a single cable. Analog output modules are protected to IP67 and do not need to be mounted in enclosures (if required, an additional 100 feet of cabling can be used from the analog module to the host controller).

For more information on Intellinder, contact Parker Hannifin’s Industrial Cylinder Division.

View our solutions on display at this year's HydroVision Expo, July 14-17 in Portland, Booth #10071 and also arrange an exclusive visit on July 15th to our Mobile Technology Showcase Exhibit in the greater Portland area (lunch and transportation provided). This event is hosted by Parker and its local Portland partner, Western Integrated Technologies. Register to be contacted, and learn more about our unique technologies and products in a relaxed setting (limited invitations- please RSVP by July 6th).

Article contributed by Bruce Besch, Industrial Cylinder Division, Parker Hannifin

Smart Cylinders Reduce Operational Costs

Hydraulic Power Units Control All Functions of Hydro-electric Turbine 

Innovative New Fluid Purifier Saves Time, Money in Hydroelectric Plants

Essential Factors for Selecting Hydraulic Cylinders for Tough Operating Environments in Aluminium Processing

Hydraulic Technologies and Key Markets

New Wiper for Hydraulic Cylinders with Integrated Dirt Shield

IFPE 2014 Showcases Innovative Products and Systems for Heavy-Duty Vehicle Design

Power generation environments are tough on hydraulic and other types of cylinders (including pneumatic and electro-mechanical). Vibration, dust, gravel, corrosives, chemicals, axial load, and side load can make it a challenge for engineers to monitor hydraulic cylinders in various power generation applications, including gate actuation and governor control. Standard approaches for  building redundancy into monitoring devices involves time-consuming extra steps, such as adding structures to hold multiple sensors to the exterior of the cylinder or coming up with ways to keep the rod from turning—all of which add time and cost.

A smarter solution

To improve this process, Parker Hannifin has developed a new line of "smart cylinders" enhanced with the new Intellinder™ sensor that eliminates these extra steps and streamlines operations. Key features include a unique positional bar code pattern etched on the cylinder’s piston rod and a highly engineered universal optic reader. The reader is standard across all stroke lengths, eliminating the need to stock multiple probes. Quick change out, non-pressurized housing allows for easy replacement without cylinder removal. With resolution up to 0.001 inches and speeds up to 40 inches/second, Intellinder also has the ability to deliver integral health monitoring and true redundancy. Now power-generation engineers have a fast, efficient, and accurate method for position monitoring, compared to standard methods like magnetostrictive sensors, variable resistance sensors (string pots), and laser gauges.  

Parker’s Intellinder-enabled smart cylinders include hydraulic, pneumatic, and electro-mechanical designs that are designed to withstand harsh environments in hydroelectric plant and dams, gas turbines, wind turbine rotors, and solar panel tracking. Intellinder-enabled cylinder and actuation system features and benefits include:

• Extreme operating temperature rating (-40o to 221o F, 40 to 105 C)
• Remains impervious to electronic noise and has been tested to ensure signal strength in the most rigorous applications
• Steel and stainless construction available as NFPA tie rod or round line design
• Universal across a wide range of cylinder bore and rod diameters, with stroke lengths up to 20 feet
• Multiple Intellinder-enabled cylinders can be connected to a single bus, offering reduced installation and commissioning costs—installation is virtually plug-and-play
• Exterior mount, non-pressurized, non-contacting sensor that is easy to replace
• CAN communication to signal conditioning electronics allow long cable runs

First of its kind

This type of smart cylinder is the first of its kind for the power-generation market. The pattern on the rod is read optically from many sensors, making it easy and affordable to achieve dual, triple, and quadruple redundancy. By integrating a highly engineered sensor directly into the hydraulic, pneumatic, or electromechanical actuator, the time and cost associated with gun drilling, as well as unprotected external sensors with complex linkages, is eliminated.  

Standard positioning technologies all have limitations, including short strokes, dead zones, calibration needs, water ingression, temperature range restrictions, interference from contaminants, annoying electrical noise, and time-consuming removal and repair. These problems add inefficiencies to power-generation operations, increasing operational cost. Intellinder-enabled cylinders eliminate these issues and streamline operations, reducing overall operational costs by 20 percent or more compared to standard approaches.

To learn more about Intellinder, stop by Parker's main Booth 2013 at the upcoming PowerGen International Show December 9-11 at the Orange County Convention Center in Orlando, Florida. A press conference on this and other Parker product innovations will be held during the show on Wednesday, December 10, at 2:00 PM at the convention center, Room W207A.  

For full details on other products being launched, please visit our PowerGen show page.  

Article contributed by Bruce Besch, Advanced Motion Products Manager for the Industrial Cylinder Division of Parker Hannifin

High-production shredding applications produce tremendous shock in hydraulic systems. Hydraulic transmission design, shaft speed and operating torque are just the beginning of the decision-making process when selecting a pump and motor. There are 12 technical questions that need to be addressed between the shredding design team and the hydraulic pump and/or hydraulic motor manufacturer.

Reducing material – appliances, concrete, tires, etc. – into smaller particles for recycling re-use is the ultimate goal of a shredding system. Hydraulic technology is a natural fit for both systems with gearboxes and those that utilize high-torque, low-speed motors as a direct drive.

In operation, high-production shredders experience system shock when the shredding cutters jam and reverse direction. Since some cutters can cut in both directions, it may only take a fraction of a revolution of the cutter shaft to create what becomes a ‘violent event’ prior to the reversal cycle. High-dynamic loads with system pressure spikes prior to, or during the reversal of, are common with in-feed systems for hammer mills.

These ‘violent events’ can cause instant pressure spikes from 700 to 5,000 psi within milliseconds (ms). Every pump manufacturer has an approach for rugged, heavy-duty shredding applications, as well as how the pressure spikes will be accounted for. A common approach is across a relief valve. In Parker’s Gold Cup Pumps (Figure 1), it is the valve-block technology (Figure 2) that cuts off pressure spikes.

Before designing a system, it is important to have a technical discussion between the shredder team and the hydraulic pump/motor manufacturer. There are 12 questions that need to be taken into consideration. This post touches on the first three questions.

Register to receive the full white paper "12 Hydraulic Pump/Motor Selection Considerations For High-Production Shredding Applications."

Understanding the cooling capacity often dictates whether or not an additional pump is required or if it is necessary to increase the pump flow of an existing charge or boost pump. For system cooling, an important consideration is the ambient temperature where the machine will be located and operating along with the temperature of the cooling medium (likely water). It is important to know how much charge or replenish pump flow is required to exchange and cool the fluid. If there is an inadequate heat exchanger or cooling fan, it may be required to pull additional fluid out of the system to cool it. As a rule-of-thumb, cooling capacity should be sized at about 25 to 30 percent of full system flow.

Overall pump efficiency is a combination of the mechanical and the volumetric efficiency. Understanding fluid and mechanical losses is important to the system. Designers have to ensure that the amount of horsepower needed to do the job at the speed desired can be achieved. For example, as the machine becomes loaded and system pressure rises, volumetric efficiencies can change, resulting is slower machine operation.

Knowing the operating conditions where the pump and motor will provide the highest efficiency is critical in system design. The key is to size components to be able to run at or near where one can achieve the greatest output torque or horsepower. For example, if one runs a pump at low displacement where the swash plate angle on the pump is at a low angle, the pump is less efficient. Pump manufacturer catalogs include efficiency curves that show the efficiency at different pressures. Overall efficiency of a typical hydraulic pump will improve as the system pressure increases, but may also have a tendency to have a slight drop off as it approaches maximum pump pressure ratings. Operating the pump where it is most efficient will make system-operating conditions efficient as well. In general, there is a trade off when it comes to efficiency and life: Max Flow (Q) x Max Pressure (P) = Max Efficiency (%) = Minimum Life.

Register to receive the full white paper "12 Hydraulic Pump/Motor Selection Considerations For High-Production Shredding Applications."

Article by David C. Ebert, Product Manager, Parker Hannifin Corporation.

This whitepaper was originally published in www.fluidpowerworld.com, volume 2; number 1; February 2015

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Across the nation, municipalities are exploring options to reduce the emissions of their sanitation fleets. Some communities make a big dent in reducing emissions with the employ of heavy duty natural gas trucks. Others focus more on the upgrade of existing fleet vehicle componentry and equipment to cut emissions where they can. There are many areas, in the refuse industry particularly, with vehicles that can be explored to reduce the carbon footprint of each vehicle. 

A cylinder that lasts longer and creates less emissions is one area. In general, hydraulic cylinders have be robust to withstand the service life of a refuse vehicle because the environment is so corrosive. Parker’s NG High-performance cylinders with Global Shield Coating Technology are field proven to reduce CO2 emissions by up to a ton for each cylinder used in a fleet. The reduction is achieved through the elimination of chromium and related fumes and the overall reduction of energy used to conserve natural resources and reduce the carbon footprint.

The cylinders that are used to lift, compact and convey trash are repeatedly subject to impact, moisture and corrosive surroundings that make increasing vehicle uptime a constant test. The Global Shield technology has been proven to eliminate EPA concerns regarding environmentally hazardous Hexavalent Chrome and Nitride coatings.

The installation of Parker cylinders with Global Shield coating on new vehicles and the replacement  of worn out OEM original installs can contribute significantly to a community’s goals for reducing emissions.To learn more about Global Shield technology, download the product brochure.

Visit Parker at WasteExpo 2015 booth 2785 and learn how waste and recycling companies can maximize efficiency and profitability while reducing their environmental impact.  

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Hydroelectric plants, Parker and their distributors / integrators make powerful teams in the area of power generation support and technical expertise. Carter Lake Hydroelectric, adjacent to the 112,000-acre-foot lake of the same name in northern Colorado, has benefited from a custom solution for their hydro dam project. As a Parker hydraulic systems Integrator, Western Integrated Technologies designed and manufactured two hydraulic power units for Gilkes, a UK-based manufacturer of hydro-electric turbines generators(Francis hydro). Western Integrated was able to provide Gilkes and Carter Lake - with a fully integrated and comprehensive solution. They leveraged the broad variety of specialty components, manifolds, fluid conveyance and condition monitoring, and sensors that Parker offers for this hydro dam governance application. 

The two Francis hydro turbines are part of a new hydraulic systems integration installation that controls the flow of water to a distribution canal from an existing mountain lake - Carter Lake in Colorado.  A large pipe from the lake carries water down to the powerhouse where the two hydro turbines are installed,. The power in the flowing water spins the turbine which spins a generator that produces electric power. 

After the energy from the flowing water is reduced at the turbine, the water is directed to the distribution canal and on to homes and businesses. 

There are several needs at the client level, namely to reduce turbine downtime and maintenance, while optimizing running efficiency:

• Health and operation of the hydro turbine
  • Keeping hydraulic oil clean and moisture free 
  • Eliminating corrosion, and leaks from piping and fittings
  • Pressure and overall system condition monitoring
• Wicket gates precise control to control volume of water that flows through turbine. 

Each hydraulic power unit is a fully integrated package of controlling all functions of the hydro turbine.  Each Francis turbine has a brake, a turbine inlet valve, a turbine bypass valve, and a wicket gate operating assembly that needs hydraulic oil under pressure to control each function. 

Parker components have be used in all key areas: valves, accumulators, gear pumps, filters, dessicant breather, transmitters/switches, and ALok fittings. Each function uses the motion from a hydraulic cylinder (servomotor) that is controlled with directional valves, with the wicket gate servomotors being controlled with a precise proportional valve.  

The hydraulic oil from the reservoir is pumped to and stored in bladder accumulators from dual redundant electric motor/pump combinations utilizing Parker gear pumps.

 

Keeping Hydraulic oil clean

The hydraulic oil is kept clean by flowing through a Parker WPF pressure filter and the return oil is filtered

through a Parker low pressure tank top return filter. The oil in the reservoir is kept moisture free by using a desiccant breather (Parker) to remove any moisture from the incoming air. The complete hydraulic power unit is plumbed with stainless steel tubing using Parker ALok fittings for interconnections.

Hydraulic system check valves, relief valves, unloading valves are Parker cartridge valves that are machined into custom designed manifolds. For individual pressure monitoring of certain functions, Parker test points are used. Parker electronic pressure transmitter/switches are used for pressure monitoring and lead/lag motor pump control. 

  Precision required

The wicket gates must be precisely controlled because their function is to control the volume of water that moves through the turbine. The volume of water equates to turbine speed and the speed must be very accurate for proper generator frequency output. A Parker proportional valve with onboard electronics coupled to a Parker PID module and a position feedback device, “close the loop” to maintain very precise wicket gate position and thus generator frequency. Additional Parker manual valves are used in parallel to the electrically operated valves and can be used in an emergency to operate the turbine in times of power failure.

  HydroVision Conference 

View our solutions on display at this year's HydroVision Expo, July 14-17 in Portland, Booth #10071 and also arrange an exclusive visit on July 15th to our Mobile Technology Showcase Exhibit in the greater Portland area (lunch and transportation provided). This event is hosted by Parker and its local Portland partner, Western Integrated Technologies. Register to be contacted, and learn more about our unique technologies and products in a relaxed setting (limited invitations- please RSVP by July 6th).

 

 

Article contributed by Todd Yoshioka, Parker Territory Manager and Western Integrated Technologies. 

 

 

 

 

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Sources:

Carter Lake:   Images used with permission. Additional info on this project see link:   http://www.poweringthewest.org/tag/carter-lake-hydroelectric-project

 

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The industrial demand on hydraulic products with outstanding mechanical properties increases continuously. High pressure hydraulic products require high strength structural components. While for stationary applications, the higher pressures can be covered by heavy, thick walled metal products without reduction in the customer values, mobile applications have to seek for alternative designs and technologies.

Based on the requirement changes, Parker started 20 years ago to investigate a totally different approach. The outcome were ultra-lightweight hydraulic actuators with cylinder barrels supported by carbon fibre reinforced plastics. The resulting Parker Lightraulics® tool cylinders are made from carbon fibre composites and high performance lightweight alloys that are typically more than 60 percent lighter than the comparable steel actuators.

On construction sites in several operations hydraulic actuators are pushing bolts, tensioning wires and lifting heavy elements. Usually such operations take place at different locations all over the construction site, quite often in areas with limited access. Therefore the required equipment has to be portable, compact and easy to handle. On the other hand, force requirements are increasing continuously at the same time. The standard equipment for such large forces is bulky and heavy high pressure hydraulics. New technologies and materials are the only solution to overcome the conflict of interests.

High strength steels are traditionally used for common industrial applications. If lightweight is required, the development of new lightweight alloys and their joining technologies is the common approach. Depending on the level of weight efficiency of the original design, utilization of high performance metal alloys, the current state-of-the-art lightweight solution is typically based on aluminium or titanium. Because for metals an increase in strength typically results in low ductility and, correspondingly, reduced fatigue performance, their benefits for actuators are rather limited. During the last decades, developments and products of composite materials moved into the focus as a reasonable alternative. Incorporation of fibre reinforced plastics can overcome the conflict of reduced fatigue at higher strength. They offer dramatic weight savings potential and exceptional burst and fatigue strengths.

Parker recognized the conflict of increasing demand of high pressure equipment and the request for lightweight products. As a solution, different series of Lightraulics composite tool actuators were developed. These lightweight actuators are used for pressing, lifting, extracting and tensioning operations and are the result of combining lightweight materials with innovative manufacturing techniques and designs to provide exceptional portable power for a wide range of applications. The extremely low weight allows the operator to quickly and accurately position the cylinder or to move it from one place to another. The result is a reduction in transportation time and equipment, higher productivity and healthy working conditions for the end user.

To learn more about Parker's unique design, register to see the full white paper.

Article by Dr.-Ing. Olaf Stelling, the Value Stream Manager for the Composites Technologies Europe Business Unit of Parker Hannifin in Stuhr, Germany. He holds a diploma in Production Technologies and a PhD on New Developed Lightweight Aluminum Alloys, both from the University of Bremen in Germany. He began his career with Parker in 2010 but previously held research engineering positions at the Material Testing Institute University of Stuttgart and the Foundation Institute of Materials Technology, Department Lightweight Materials in Bremen.

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During the last decades, the market share of products made of reinforced plastics increased rapidly. The low density, corrosion resistance and high fatigue performance of such materials provide a wide range of benefits for different applications. Parker Hannifin has developed fully composite hydraulic cylinders for 380 bar applications which are up to 60 percent lighter than their standard steel cylinder equivalents. The fully composite cylinders were tested extensively under various mechanical and environmental influences to verify the robustness of the products. The results confirmed that the new composite barrel technology for hydraulic actuators is competitive to standard metal solutions while providing further benefits in terms of weight and corrosion resistance.

Industrial demand on products with low density in combination with outstanding mechanical properties requires continuous R&D effort. While for metals the development of new lightweight alloys and their joining technologies is the common approach, developments and production of composite materials moved into the focus as a reasonable alternative. Compared to metal matrix composites, fibre reinforced plastics offer additional weight savings by the low density of the matrix material. 

Figure 1

For high pressure hydraulic cylinders, accumulators and pressure vessels typically high strength steel alloys are chosen. Such materials are not suitable for lightweight applications. Depending on the level of weight efficiency of the original design, utilization of high performance metal alloys, typically based on aluminium or titanium, is the current state-of-the-art lightweight solution. Because an increase in strength typically results in low ductility and, correspondingly, reduced fatigue performance, their benefits for actuators are rather limited. Incorporation of fibre reinforced plastics can overcome the conflict of reduced fatigue at higher strength. Ideally, the load-bearing structure of the products would be made entirely out of composite, thus without a metallic liner, and without a metallic barrel that supports the axial loads applied on the end caps. Parker has developed an ultra-lightweight high pressure fully composite hydraulic cylinder series called Lightraulics®. An example of a Lightraulics® C-Series composite hydraulic actuator is shown in Figure 1.

To learn more about Parker's new technology, register to see the full white paper.

Article by Dr.-Ing. Olaf Stelling, the Value Stream Manager for the Composites Technologies Europe Business Unit of Parker Hannifin in Stuhr, Germany. He holds a diploma in Production Technologies and a PhD on New Developed Lightweight Aluminum Alloys, both from the University of Bremen in Germany. He began his career with Parker in 2010 but previously held research engineering positions at the Material Testing Institute University of Stuttgart and the Foundation Institute of Materials Technology, Department Lightweight Materials in Bremen.

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The selection of a motor for a hydraulic application can be complicated. The following technical article breaks down the process discussing fundamental selection factors.

A hydraulic motor is a hydraulic actuator that, when properly connected into a hydraulic system, will produce a rotary actuation. This can be unidirectional or bidirectional depending on the system design. Motors are similar in design to pumps only where a pump takes a rotary actuation to move hydraulic fluid out of the unit, whereas a motor will take flow into itself and put out a rotary actuation.

The motor selection comes first in the process because application design best practices require that you start with the load requirement, then work back to the prime mover—the pump that will put the fluid power into the motor selected to deliver the performance goal.

Each motor type—gear, vane, in-line piston, bent-axis piston and radial piston—has a specific performance profile. So, knowing the application performance requirement and which motor type best meets the objective is the first step. Then it’s necessary to evaluate the design advantages of your motor options along with the degree of complexity you want for the overall system.

In the end, it all goes back to the application’s performance expectations. Some have severe duty cycles, while others do not. If, for example, you consider running a low-efficiency, lighter-duty motor into a higher-duty cycle application, the life of the motor will be less than the life of a higher-duty cycle motor that is designed to operate in those types of environments. It is important to understand what operating pressures and flows are required for the motor selected to achieve the application performance expectations.

Each motor type has its own set of applications where they are a better choice than others. For example, if a small gear motor designed to operate at a max of 3,000 psi and 1,000 rpm is put into an application that requires it to run consistently at 3,000 psi and 1,000 rpm, the motor will be running in a “corner” overstressed condition and have a reduced life—even though it is technically within its ratings. The better motor choice would be a motor with higher ratings that will live longer in the application. Granted, there is a greater cost in going with a higher rated motor. The final decision always will depend on what is required in terms of application performance and motor life versus where you want to be with cost.

To learn more about motor selection, register and download the full white paper. 

Article by Justin Wheeler, CFPHS, C-Series/Bent Axis Project, Manager, Hydraulic Pump Division of Parker Hannifin and originally appeared in the October 2015 issue of Fluid Power World. A 2000 graduate of The Ohio State University, Wheeler has been involved in hydraulic and electrical systems engineering for 15 years.  Wheeler is listed as an inventor on two U.S. Patents — US7134513 (“Drive Mechanism for a Boring Machine”) and US7500530 (“Control System for Construction Equipment’)."

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Actuation systems must be efficient, precise, and durable enough to withstand harsh power-generation environments. Parker Hannifin Corporation has developed a hybrid actuation system (HAS) that is ideal for renewable-energy actuation applications, such as those used with solar panels, wind turbines, and hydro-electric dams.

The new hybrid design combines the controllability of traditional electromechanical actuators with the power density, longer life, and resistive-force capabilities of traditional hydraulic systems. The result is an improved actuation system for wind and hydro and other renewable energy systems, with a wider range of capabilities.

More efficiency, less maintenance

This high-efficiency, modular system allows for various traditional cylinder mounting configurations and stroke lengths. The hybrid design is a fully self-contained system with no hydraulic hoses or power units. Hybrid hydraulics achieve exceptional economies of scale, with the ability to move over a megawatt from a single point. This makes HAS a good choice for large or small arrays.

Serviceability is built into the design. The system can be serviced on site, with simple line-of-use replacement, allowing for a quick change-out in the field. The system features simple, two-wire operation and is available with AC and DC supply voltages.

Other highlights include:

• Low amp draw, 50 percent duty cycle, high-efficiency tracking solutions
• High locked hold force to withstand wind gusts
• No reduction in life (a common problem with screw-type actuators when loaded)
• Surface preparation for outdoor installations
• Stainless steel rods for extreme corrosion prevention
• Heavy chrome-plated rods with optional Global Shield™ rod coating
• Available with Intellinder™ continuous feedback or end-of-stroke, stroke-to-go switch options
• Stainless-steel transfer tubes, no extra plumbing required

For solar panels, HAS is completely self-contained, combining a double-acting actuator, pump, and electric motor that eliminate nearly all leak paths into or out of the package. Parker engineers designed a hybrid actuator into the pitch system so designers can move more photo-voltaic panels with fewer actuators and controls, resulting in lower installation costs and longer service over the life of the solar field. The design offers clear advantages over comparable electromechanical actuator (EMA) systems because all the internal-wear items are permanently lubricated for extended life. The power density of HAS is typically three times that of a comparable EMA.

Add Intellinder™ sensor for even better performance

Another benefit to the Hybrid Actuation System is that it can be configured with an integrated Intellinder sensor (also available on Parker’s hydraulic, pneumatic, or electromechanical actuators). This sensor eliminates the time and cost associated with gun drilling, as well as unprotected external sensors with complex linkages.

Cylinder feedback installation is virtually plug-and-play. Intellinder-enabled cylinders include hydraulic, pneumatic, and electro-mechanical designs that are engineered to perform in harsh power-generation actuation environments like solar fields and wind farms, as well as fossil-fuel applications. Intellinder-enabled cylinder and hybrid actuation systems can withstand vibration, dust, gravel, corrosives, chemicals, axial and side loads, and immersion, with an extreme temperature rating (-40° to 221° F).

See for yourself

Parker Hannifin will be demonstrating the Hybrid Actuation System at Booth 2925 at Power Gen International in Las Vegas December 8-10, 2015.  For more information, please visit our Power-Gen solutions page.

Article contributed by Bruce Besch, Advanced Motion Products Manager, Parker Hannifin Industrial Cylinder Division. Learn more about our hybrid actuation systems and cylinders at our web page, or contact an Industrial Cylinder Division engineer at 847-298-2400. 

Additional resources:

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Hydraulic accumulators are the dextrose tablets of the engineering world, providing fast access to stored energy when required.

At supersonic speeds, having instant access to energy reserves is critical; for BLOODHOUND SSC, that could mean making sure the car stops safely before running out of desert.  At 1,000 mph every millisecond counts, so Andy Green will rely on powerful air brakes to slow the vehicle from 800mph and below. But there’s also a need for instant energy as a backup – in this case, taking the form of two composite hydraulic accumulators.

After BLOODHOUND's EJ200 jet engine starts, the accumulators are charged. If a loss of hydraulic power occurs at any point, stored energy in the accumulators will be ready to deploy the air brakes at a controlled speed.

Originally, BLOODHOUND SSC was going to house one large steel bladder accumulator, high in the vehicle. However, project engineers were concerned about the potential height of the centre of gravity and symmetry of mass about the centerline axis; at such high speeds, the car must be very stable about the yaw axis.

Product size, weight and placement are also key factors for BLOODHOUND SSC; there’s a huge amount of technology packed into the car.  The team needed a lightweight accumulator that could fit into a compact design envelope.

Parker’s project team spotted that using two composite piston accumulators would meet all of these demands. Compared to bladder accumulators, our recommended piston counterparts were much smaller and can deliver more of the available oil capacity. They also weigh considerably less than a standard steel product.

With this in mind, Parker sent some models to BLOODHOUND’s engineers - kick-starting an iterative process to custom-build an accumulator specific to project requirements.

High-pressure hydraulic products need strong structural components. Normally, industrial applications use high-strength steels, whilst more expensive lower-density alloys are used in lightweight applications. But whilst high-performing metallic alloys are very strong, these benefits can be outweighed by decreased ductility and reduced fatigue strength.

Composites are an ideal reinforcement material for hydraulic products. They offer higher strength and superior fatigue properties compared to most metals.  Traditionally, composite accumulators have used metal liners with an outer composite reinforcing structure, due to the high-stresses involved; but Parker’s engineers have been working hard for more than 10 years to develop a high-performance hydraulic product that is almost entirely made of composites.

Rather than simply reinforcing a metallic barrel, Parker developed a specially-formulated plastic liner, integrated into the carbon fibre reinforced epoxy composite product.  This plastic liner is lighter and more cost-effective than thin-walled metallic barrels, yet offers superior fatigue life properties over most metals.

The barrel design concept consists of two parts – an inner liner and outer barrel. The fully composite inner liner carries the hoop loads of the internal pressure, while a fully composite outer barrel is responsible for supporting the axial loads. To allow maintenance of seals, the outer barrel has metal inserts integrated into the composite via a patented technology, which provide a threaded interface for the end caps at each end of the barrel. With everything but the threaded end caps constructed of composite, the product is up to 60 per cent lighter than standard steel accumulators.

The fully-composite liner is cheaper to manufacture, lighter, and offers higher burst and fatigue strengths than a composite reinforced metallic liner. The fully-composite outer barrel is also lighter and offers outstanding burst and fatigue strengths.

Table 1 below compares a sample 15-litre Parker composite accumulator to similar performance steel piston accumulators, using data published in several major hydraulic manufacturers’ product catalogues.

Table 1: composite accumulator performance

Typical steel piston accumulator

Parker composite accumulator

Volume  [L]

15

15

Pressure [bar]

350-375

380

Weight [kg]

90-131

26

The development phase incorporated substantial testing. In particular, numerous burst tests were performed to confirm the structural integrity of the product was well above regulatory requirements. Due to the typically high-cycle lifespans of accumulators, several samples were fatigue tested (up to approaching six million cycles). Drop tests and impact resistance tests were also performed in preparation for future regulatory approvals.

In addition, the product was deliberately designed to have a safe failure mode in the event of over-pressurisation. Before reaching a pressure level where the accumulators could dangerously rupture, they are designed to leak at a rate that prevents further pressurization.

To confirm this for the BLOODHOUND accumulators, Parker made an additional accumulator only for burst testing. As expected, this sample leaked but could not be made to rupture - offering a fail-safe mode to the BLOODHOUND team, should the completely unexpected occur.

Analysing processes was another key step in the chain. This involved exploring options to achieve a good surface finish, make the product round and reduce the likelihood of cracking.

So far, Parker’s composite piston accumulators have primarily been used in controlled conditions - such as for testing in academic environments. However, discussions are progressing about the potential for launching the product to specific niche markets.

Cost-wise, composite accumulators are more expensive than standard steel versions, but around the same price as stainless steel products. Whilst unlikely to be adopted for mainstream applications where traditional steel is more cost-effective, they are ideally suited to corrosive environments and applications where weight is a key priority.

Composites are an excellent option for industries such as oil and gas – offering the equivalent corrosion resistance as stainless steel accumulators, but with the added benefit of being much lighter, meaning lower transportation costs and easier portability. Subject to securing the necessary regulatory approvals, this type of product has significant market potential in the years ahead.

In the meantime, of course, all eyes will be on BLOODHOUND and the test runs scheduled next year.  And as pilot Andy Green powers his way across the South African desert with Parker's composite accumulators on board, he’ll have instant access to a big energy boost if and when he needs it.

Feature photo credit: Photographer Stefan Marjoram 

Content by Mark Cattermole, Parker Sales UK (pictured) and Bruce Otte, Hydraulics Division

Related links

Watch the video: Parker’s BLOODHOUND SSC airbrake system

Check out our latest news on the BLOODHOUND website: Hydraulic power packs streamline testing for BLOODHOUND's world record bid 

Read the blog: Lightraulics C-Series Actuators: High Pressure Hydraulics for Lightweight Applications

Want to know more?

If you’d like to keep track of Parker’s support to the BLOODHOUND project, please join the mailing list to receive occasional updates.

You can also find some great resources on BLOODHOUND'S YouTube channel.

This post builds on an article covered in The Engineer in January, and provides additional information about Parker’s contribution to the BLOODHOUND supersonic vehicle.

As fuel costs continue to rise and vehicle emissions standards grow increasingly stringent, both municipal and private fleet managers must find new ways to contain operating costs by increasing the efficiency of their operations.

It is also evident that virtually every company serving the waste collection and processing industry is committed to their obligation to act as environmental stewards throughout their operations and in their products.

Parker shares this focus and is partnering with its customers to develop and implement new products and systems which will help the waste industry achieve their environmental and sustainability goals.

Parker’s Global Shield Coating is a new exclusive plating technology available from Parker. When applied to cylinders used throughout the waste industry, whether on refuse collection vehicles or industrial recycling or shredding facilities, the Global Shield coating provides extended cylinder life in abusive environments without the negative environmental impact that occurs with hexavalent chromed solutions.

Global Shield coating provides up to eight times the corrosion resistance of a traditional nitride or chrome coating, reducing the total cost of ownership.

Parker’s Intelligent Flow Control (IFC) system architecture is applicable to both mobile and industrial motion and control applications. IFC utilizes electronic displacement controlled pumps, available from Parker, in conjunction with multiple valve designs to provide significantly faster system response to improve productivity, often by 15-20%, while reducing parasitic losses experienced in open center systems or in the form of margin pressure savings in load-sense systems.

RunWise is an advanced series hybrid drive system with brake energy recovery. The brake energy recovery system converts the vehicle’s kinetic energy into stored energy by compressing nitrogen gas in a storage device called an accumulator. This stored energy is then released during acceleration to reduce the energy required from the engine to propel the vehicle.

Through the series drivetrain architecture, the engine can be operated at speeds independent of vehicle speed. As a result, the engine always operates at the ideal spot for any power level demanded by the vehicle operator, which can be a limitation of a conventional transmission.

By reducing energy demand, RunWise reduces fuel consumption, regardless of fuel source, by 35 to 50 percent, depending on route density and operating conditions. A truck equipped with RunWise hydraulic hybrid system can consume 4,300 gallons less fuel per year than a truck utilizing a standard transmission. This equates to an average annual reduction in CO2 emissions of 48 tons per year, equivalent to removing 10 midsized cars from the road or planting 1,100 trees and letting them grow for 10 years.

In addition to reducing fuel consumption and emissions, Parker’s brake energy recovery technology lengthens the brake replacement cycle to one or two brake jobs throughout the life of the truck (depending on duty cycle), dramatically reducing maintenance costs as well as the disbursement of brake dust into the atmosphere. By improving acceleration and braking, RunWise can also reduce collection times by 1-2 hours.

Read a white paper which explains how RunWise is helping to reduce fuel consumption and emissions in refuse applications. 

Parker is committed to maintaining its leadership in advancing motion and control components, systems and technologies with focus on improving its own environmental footprints as well as assisting its customers and served markets in achieving their environmental goals.

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