When you are challenged by the demands of 12,000 ft ocean depths for subsea blow out preventers (BOPs), piston accumulator technology is the right choice. 

Oil and gas accumulators can be used for blowout preventer, offshore rig and mud pump applications. Designed with considerable flexibility, you can find an appropriate type to match your volume, pressure and the type of fluid required.

Accumulator systems include bladder, diaphragm, and piston, which are available commercially. Two more designs available in oil and gas accumulators are bellows and composite overwrapped. Bellows accumulators are mainly used in extreme abrasive and harsh environments. Composite overwrapped accumulator are used to increase performance and reliability of engineered components.

The oil and gas markets demands high-pressure piston accumulators. With working pressure ratings up to 30,000 psi and capacities of 160+ gallons, Parker accumulators meet the tough demands of deep, subsea oil and gas applications, including blowout prevention systems (BOPs), well-head control panels, “Christmas” trees and other emerging drilling systems.

In addition to high pressure-rated units for subsea applications, Parker offers piston accumulators rated to below -40°F. This increased flexibility at extreme temperature ranges offers GAD’s customers the ability to operate their equipment in virtually any environment. For additional information, contact an Applications Engineer at the Parker Global Accumulator Division (GAD) in Rockford, Ill., at 815.636.4100.

Parker’s piston accumulator capability includes 1.5- to 25-inch bore sizes with capacities up to 200 gallons. All are custom designed to fit a specific application utilizing a total custom-based systems approach that includes application engineering and worldwide support. Currently, Parker lead-times for both stainless and carbon steel units are significantly shorter than the rest of the marketplace.

The piston accumulators provide major advantages in terms of the energy output of the system and maintenance of the installation:

• Reduction in working costs
  • Reduces installed electrical power
  • Significant energy saving
• Increased lifetime of equipment
  • Reduces pulsations
  • Protects against pressure peaks
• Reduction in maintenance cost
  • Reduces wear of hydraulic components
  • Requires minimum maintenance of the installation

Parker is supplying 80-gallon piston accumulators specifically designed and built in special grade stainless steel to meet the demanding requirements of the 10,000 to 12,000-ft subsea ocean floor environment. The new 80-gallon accumulators have a 14-inch bore and are rated to 7500 psi design pressure. All Parker units feature the required pressure vessel certifications for worldwide use in multiple locations including the following:

• ABS – American Bureau of Shipping
• DNV – Det Norske Veritas (E-101 regulations)
• PED – European Pressure Equipment Directive “CE” marked
• ASME – American Society of Mechanical Engineers
• CRN – Canadian Registration Number

“Parker's work with subsea BOPs and piston accumulators is due in part to a long and productive relationship with Cameron and our ability to custom engineer piston accumulators with capacities up to 200-gallons, and with ASME ratings of 20,000 psi. To date, these 80-gallon stainless units are the largest built for today’s subsea drilling environment.”  Jeff Sage, product manager, Parker’s Hydraulic Accumulator Division

Photo Caption: Parker’s Hydraulic Accumulator Division is supplying 80-gallon piston accumulators
specifically designed and built in special grade stainless steel to meet the demanding requirements of the
10,000 to 12,000-ft subsea ocean floor environment of Cameron's BOP units

“Parker’s secured stainless steel supply source,” points out Roger Bolton, sourcing specialist, Cameron,
“allows them to meet our demanding BOP build schedules for the new generation of rigs currently under
construction for deep water ocean floor drilling. Parker has not missed a delivery date, their pricing is
competitive, and there have been no quality problems.” Cameron is a leading provider of flow equipment
products, systems and services to the worldwide oil, gas and process industries.

Article contributed by Jeff Sage, Product Manager Accumulator and Cooler Division . About Parker’s Hydraulic Accumulator Division

Parker’s Hydraulic Accumulator Division supplies the global marketplace with the broadest line of hydraulic
accumulators and accessories in the industry. For more than 50 years, Parker piston and bladder style accumulators have been improving the performance of hydraulic systems by prolonging equipment life, lowering operating costs and reducing downtime.

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The variable-speed hydraulic pump, with its potential for energy savings, power density and temporary noise reduction,  is currently the dominant pressure supply system in the media. It provides a clear example of how hydraulics can successfully participate in the evolution of electric drives. 

Promotions for the variable-speed pump like to suggest that standalone individual drives are the future for hydraulics. Electrohydraulic actuators have their uses, of course, but it is important to remember that electric motors, and their converters, are what make electromechanical drives so costly. Each drive needs a fixed motor, which makes the drive large and expensive. If this principle is applied to hydraulics, it restricts the choice of appropriate pumps to those variants that are suitable for four-quadrant operation. This limits options and increases costs as well. 

The multiple use of the electric motor in the central supply, together with the large range of suitable two-quadrant pumps (pumps in which the P- and T-attachments on the pump remain in place unchanged, regardless of the direction of flow; that is, the high pressure is always on P, and T is always connected to the tank), provide good economic arguments in favor of hydraulics as opposed to electromechanical systems. Because the central supply is connected to the drive with pipes and hoses – this is why hydraulic drives are often so compact – the power can be fed around any corner. 

When marrying hydraulic pumps with electric motors, one has to take into account the behavior of each system, as determined by its construction type, with respect to its hydraulic, electrical and mechanical characteristics. A variable hydraulic flow can be created with an adjustable-flow pump, a fixed-displacement pump on a variable-speed electric motor, or a combination of both: a variable-flow pump on a variable-speed electric motor (Figure 1). 

Figure 1

Studies so far suggest that the last of these is the most energy-efficient combination, but also the most expensive. With smaller flow rates in particular, this expense cannot be justified, and it is preferable to adopt more economical solutions involving fixed-displacement pumps. The long-established option of a variable-flow pump on a constant-speed asynchronous motor is almost unanimously considered to be the benchmark solution. 

To learn more about variable-speed vane pumps, register and download the full white paper.

Dr.-Ing. Gerd Scheffel is industrial applications engineering manager for Parker in Kaarst, Germany. He holds a doctor’s degree in hydraulics at Aachen University. He started his career as hydraulics engineering manager at Towler Hydraulics which was acquired by Parker in 1984. He served as general manager from 1989 to 2012 of the Hydraulic Controls Division and managing director of Parker Germany from 1991 to 2014.

Dr.-Ing. Roland Bublitz is industrial applications engineering manager for Parker in Kaarst, Germany. He holds a diploma and a PhD in mechanical engineering both from the RWTH Aachen University in Germany. He began his career at Parker in 2003 and worked previously as research assistant at the Institute for Fluid Power Drives and Controls at RWTH Aachen University.

This article first appeared in MDA Technologies Internal Edition, October 2015.

How VFD Technology on Hydraulic Power Units Helps Improve Performance

VFD Provides Energy Saving on Hydraulic Power Unit

VFD Eliminates Bottleneck in Canning Plant

However, there are challenges with hydraulic systems that still need some work

• The ability to adapt the machine to any load condition.
• Achieving full performance at variable load cycles.
• Machine stability and system function predictability.
• Little flexibility on how the valve functions are performing.

How does an OEM engineer develop a better system that leads to an increase in machine productivity and fuel savings, using a solid foundation from today’s technology?

Our EQA (Electric Flow Amplifier) EcoFormance technology represents one of the next significant advancements in load sensing valves. Used in hydraulic systems found in mining, forest and construction machines, this technology offers OEMs a lower risk and the gains in doing so are well defined: in tested applications, a 15% productivity increase and 22% fuel savings results. 

EcoFormance technology offers unique and useful features to achieve

• Precise control
• Improved productivity 
• Energy savings
• Easy installation

The K220LS load sensing valve with EQA technology is a result of our wide experience in mobile hydraulics, offering excellent performance, made with high grade materials and precision manufacturing. It has a wide range of selectable functions, offering great flexibility in terms of system structure in simple as well as advanced hydraulic system solutions.

By automatically adapting the meter-out pressure to the load conditions, machine control is greatly improved by the EQA technology. This is most notably useful for functions with slew or jib movements, or digger arms with over-center movement.

The K220LS load sensing valve allows instant and seamless switching between regenerative mode and double acting mode, as well as between gravity lowering and power down. The added speed and precision means more work can be done in a given time.

Minimized meter-out losses reduce fuel consumption. The increased efficiency the valve handles also means more available power for the work cycle.

EcoFormance work sections can be combined with other K220LS sections anywhere in a valve stack. Since meter in control is done the traditional pre-compensated way, the software only needs to control the variable meter-out pressure. This can easily be implemented in any OEM ECU-controller. The EcoFormance load sensing valves are available with a plug-and-play CAN interface for ultimate simplicity.

Our K220LS EcoFormance load sensing valve is a great problem solver for many functions with varying load conditions –and any kind of materials handling equipment, mobile or stationary.

• Construction Machines
• Forest Machines
• Mining Machines
• Excavators
• Backhoe Loaders

The EQA element used in the K220LS to control the variable meter-out pressure is hydraulically pressure compensated. K220LS can be equipped with hydraulic or electrohydraulic spool actuators in any combination. Each valve section can be optimized for its particular function in the machinery, with a large range of main spools, pressure relief valves, pressure compensators, signal pressure limiters and other performance enhancing functions.

• Improved machine control

• Improved productivity

• Improved fuel efficiency

• Easy implementation

• Seamless mode switch between regenerative and double acting mode

• Cavitation-free operation under all conditions

If you’re looking to maximize your hydraulic machine’s operational performance in the most cost-effective way, consider our next generation EcoFormance load sensing valve as the solution.

To learn more about the K22OLS EcoFormance load sensing valve, download the brochure.

Stop by to see a full system display and visit with Parker engineers during the MINExpo International Tradeshow, September 26-28 in Las Vegas  Booth 2851-N.

Article contributed by Per Nilsson, global industry market manager, Parker Hannifin

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From optimizing peak performance to minimizing unplanned downtime, the products and systems Parker will showcase at IFPE 2017 are designed specifically to help its customers increase their productivity and profitability.  

Every three years, more than 100,000 attendees from around the world gather in Las Vegas, Nevada for the International Fluid Power Expo (IFPE) to learn about the latest developments in construction, agriculture and a diverse range of related markets.  

Here is a look at some of the innovative new technologies Parker experts will be on-site to discuss with visitors:

Load sensing valve with EQA technology - EcoFormance

Parker’s EQA (Electric Flow Amplifier) EcoFormance technology represents one of the next significant advancements in load sensing valves. By automatically adapting the meter-out pressure to the load conditions, machine control is greatly improved by EQA technology. This is most notably useful for functions with slew or jib movements, or digger arms with over-center movement.

Used in hydraulic systems found in mining, forest and construction machines, this technology offers OEMs a lower risk and the gains in doing so are well defined: in tested applications, a 15% productivity increase and 22% fuel savings results.

A load sensing valve with EQA technology also allows instant and seamless switching between regenerative mode and double acting mode, as well as between gravity lowering and power down. The added speed and precision improves productivity, enabling more work to be done in a given time.

Electro-Hydraulic control - IQAN Connect

Parker IQAN Connect is a totally electronic approach that replaces mechanical and electromechanical systems for controlling and monitoring hydraulics in mobile machines. IQAN Connect is a digital ecosystem that ties together Parker’s smart hydraulics and electronics products to work seamlessly as a complete system.

IQAN connect offers a synergy of intelligent components and customizable software that delivers next generation connectivity while providing flexibility in design and development.

Hose selection simplified - GlobalCore

The result of a multi-year collaboration among several Parker divisions, GlobalCore is a simplified line of world-class hydraulic hoses featuring just five hose sizes and two fittings series, greatly reducing complexity to simplify ordering and inventory management.

GlobalCore hose has half the bend radius of conventional hoses with one-third less effort, reducing a customer’s hose needs by as much as half. The outside diameter is nearly 30% smaller, enabling it to fit into tight spaces or even allowing a customer to increase hose size for better flow characteristics. It has twice the impulse life of other hoses and features a highly abrasion-resistant cover, greatly extending time between replacements and minimizing downtime.

Accurate mobile diagnostics - SensoNODE and SCOUT Mobile

Abnormal temperature and pressure levels can adversely impact the function of hydraulic lines and pump systems in heavy mobile machinery. Because a machine must be operating for accurate readings, traditional wired diagnostic solutions can lead to wires or cables getting caught in moving parts, or require the installation of extra hardware.

Parker’s SensoNODE BlueTM sensors and SCOUT MobileTM  software give users an advanced condition monitoring solution that provides accurate readings without excessive wiring, allowing for mobile diagnostics with the cab door closed. SensoNODE sensors allow for accurate pressure and temperature diagnostics to avoid overload/failure or decreased operation efficiency.

Highly resilient thermoplastic components - nobrox

Parker’s nobrox® is a new thermoplastic material which exhibits excellent wear resistance, chemical resistance and resilience, reliability, ease of assembly and economy – while offering versatile uses as a sealing element, guiding element, anti- extrusion element and material for engineered components.

In the harsh working conditions of hydraulic systems, sealing materials – besides withstanding high loads and pressures – must be able to successfully resist a variety of other attacks. Environments contaminated by abrasive particles, as well as rough surfaces, mechanically attack the materials, while fluids do so by chemical means. Pressure and temperature contribute their fair share to these challenges. Seals made of the new Parker nobrox® material excel in terms of robustness against abrasion even on the harshest mating surfaces such as castings, drawn tubes or ceramics. They are compatible with all media commonly used in fluid power systems at the required operating temperatures as well.

Unmatched strength and heat resistance - Fabric Reinforced Products

Reinforcing an elastomer with fabric increases the durability and longevity of a part and provides added flame and abrasion resistance. Parker’s fabric reinforced products offer industry-leading tensile strength, pliability and fire resistance in a low cost, durable elastomeric fabric composite.

Parker fabric reinforced products come in bellows, profiles and custom shapes utilizing fabric coated or infused elastomers. They can be designed to fit any application utilizing extruded profiles, molded bellows or customizable shapes. Fabric reinforced products are designed to withstand direct flame at 2000°F for 15 minutes, and offer increased abrasion resistance for product longevity.

Visit Parker at IFPE 2017 in booth S-80242 on March 7-11, 2017 to learn more. 

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When you think of dump trucks, moving floors, oil transfers, lowboys, live floors and roll-offs, your first thought might not be Wetline Kits. Instead, you probably think about the function of each of these trucks. But, none of them could operate without a Wetline Kit and Parker has the most comprehensive configuration system. Unlike other places where you buy a generic kit for your type of truck, Parker’s Wetline eConfigurator allows the user to build a Wetline Kit needed for a specific truck.

The beauty of Parker’s eConfigurator is that there is no wasted time in parts collating, using multiple suppliers or guesswork in component selection. With a few simple questions, it will walk you through choosing your Power Take Off (PTO) down to ensuring you have all the connections you need. As you go through the process, it gives you the control to design the kit to your truck’s exact needs.

If you use your truck for different kinds of jobs, Parker also offers the ability to create a combination system that allows greater flexibility in what trailers can be connected to your truck. Parker currently offers three combos:

• The Standard Combo comes with a dump pump that is rated for up to 2500 PSI with the R/V set to 2440 PSI.  This combination is a versatile, cost-effective solution that works well in most setups. It allows you to connect dump trailers, lowboys and roll-offs. In addition, there is only one pressure setting, MPT Ports and standard in-cab controls. The Standard Combo, however, is not meant for heavier loads.
• The Premium Combo uses a pump and valve system that is rated for up to 3000 PSI. It has easy to use in-cab controls that monitor two different pressure settings (2250 & 3000 PSI), O-ring ports for leak free hydraulics at high pressures and are able to handle a wide range of loads. Having the flexibility to monitor different settings does mean there will be multiple lines and the driver will have to know which pressure line to connect when quick coupling.
• The Auto Combo, created for high flow applications, uses a pump and valve. There is no need for any special operation from inside the cab by the driver as the pressure settings are automatically monitored at 3200 and 2250 PSI. It also has O-ring ports for leak free hydraulics at high pressures, standard in-cab controls, faster unloading speeds and easy trailer connections.  

Both the Auto Combo and Premium Combo allow you to connect everything the Standard Combo does in addition to oil transfer, live bottom, frack and moving floor trailers.

“We made this easier than in the past, as this was on a manual spreadsheet that was not available online. Now, this is available to be configured by anyone, be it the end user, dealer, truck distributor, etc. The most attractive feature in this eConfigurator is it supplies a list price, BOM and an installation drawing right from the website, which makes it very simple and quick.”

George Artem, sales manager for Parker Truck Products in Canada

• To utilize the Wetline eConfigurator, simply go to our online Wetline Kits page, click the "public" button, then acknowledge the safety guidelines.
• Begin by deciding the specific application you will be utilizing and how many lines your trailer needs.  
• From there, you will need your transmission make and model number, which will allow it to tailor your part selections to your exact needs.
• After those few pieces of information, the system will walk you step-by-step through the entire list of components needed to assemble a complete Wetline Kit. 

Parker Wetline Kits and PTOs are shipped within 48 hours and are ready for immediate installation. Step-by-step prints are provided for your installer to make the installation quick and easy. 

Packing for the Wetline Kit comes in a single box, with the exception of the PTO, and includes all your selected components based on your application.

Wetline kits contain:

•   Hydraulic tank
•   Pump
•   Specialty valves
•   Hoses & fittings
•   Quick connects
•   Filtration
•   In-Cab controls to operate your truck
•   Chelsea PTOs

In addition to the convenience of having a kit tailored specifically to your truck, you also get the peace of mind of quality products. Parker offers many of the leading brands in the vocational truck industry, including Parker fluid connectors, Chelsea PTOs, commercial pumps, cylinders, Gresen valves and Racor filters. Parker is the only company to manufacture every component in a wetline system for the vocational truck market, so you know every part of the system meets Parker’s high-quality standards.

The eConfigurator is straightforward and designed to get you exactly what you need for your truck, with no guess work. In a world where taking chances could mean your truck being down and not getting the job done, Parker Hannifin is there with the tools to make building and maintaining your truck easy.

Meet our team at this year's Work Truck Show, Indiana Convention Center, Booth 3011 and Booth 3412, Indianapolis, Indiana, USA. Our divisions represented are Chelsea Products Division, Electromechanical and Drives Division North America and Gas Separation and Filtration Division. Stop by our booth and pickup your 2017 Chelsea Power Take-Offs Quick Reference Guide. 

Article contributed by Nicholas Roberto, national sales manager, Vocational Truck Team, Parker Hannifin.

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Modern industrial machinery is creating ever-increasing demands on hydraulics to provide more efficient and quieter solutions with a smaller footprint, while maintaining the benefits traditionally associated with hydraulic systems, i.e., high power density, precise control and enduring performance. But historically, these benefits have come with the high cost of inefficient energy allocation, heat generation and noise. The variety of discreet components constituting each hydraulic system has complicated the challenge.

No two hydraulic systems are identical, and effective integrations require a deep understanding of

• Hydraulic systems 
• Hydraulic pumps
• Electric motor technologies 
• Control algorithms

– and how these interact with each other. 

Conventional hydraulic power units require oversize pumps and motors to ensure performance during a system’s highest duty-cycle demands. When energy costs were predictable and environmental regulations less stringent, the wasted energy and high CO2 emissions were not seen as problematic. In today’s eco-conscious and globally competitive economic environment, a transition to systems in which power is precisely modulated to the requirements of specific tasks within highly complex hydraulic systems is essential.

This is where Drive Controlled Pump (DCP) technology can provide a solution to address the challenges of 

• More demanding applications
• Rising energy costs
• Rising staff costs
• Greater environmental requirements

Download our white paper to learn more about the use of DCP technology in applications such as automotive, metal forming, rubber production, plastics, retrofit design, test stands, general industrial, machine tools, and die casting.

Contributed by: 

Rashid S. Aidun (top) who draws on his electrical and fluid power background to create custom drive controlled pump solutions. Prior to joining Parker 16 years ago, he worked as an industrial manufacturing and fluid power and controls engineer for various OEMs. He has a BSME from Syracuse University.

Dan Detweiler (bottom) is a value added systems and technical services manager for Parker. He has a BS in Electronic Engineering Technology from the College of New Jersey. Dan joined Parker with Miller Fluid Power acquisition in 2001, and has held account manager, application engineer, and regional manager roles during his 28 years in the fluid power industry.

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How VFD Technology on Hydraulic Power Units Helps Improve Performance

Hydraulic Power Units Control All Functions of Hydro-electric Turbine

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Rising temperatures - which lead to water evaporation and loss of coolants in critical wind turbine cooling systems – may cause 1.5 MW wind turbines to overheat. Fortunately, there's a solution to help keep your wind turbines running efficiently and in good working order.

If you are operating a 1.5 MW wind turbine with an open-loop cooling system, you may have a costly problem on your hands - one that you might not even be aware of. By its nature, the open-loop system allows for water to gradually evaporate from the water-glycol coolant in the insulated gate bipolar transistor (IGBT) circuit, especially during warm weather. Water evaporation lowers the coolant level and elevates the mixture’s concentration, inhibiting the cooling properties of the fluid and potentially compromising the IGBT.

Loss of those IGBT components due to wind turbines overheating result in significant downtime and hardware losses, to replace. To avoid this, wind turbine maintenance teams commonly “bandage” the problem with a regular cadence of coolant monitoring, water replenishment and re-balancing of the cooling fluid mix. But this costly maintenance solution requires taking both the turbine and transformer offline - resulting in significant downtime and revenue loss for the wind farm.

For more detail on how our engineers' design custom, precision-engineered solutions that help even the most sophisticated wind power plants generate wind turbine energy more efficiently while improving reliability and up-time download our wind turbine solutions brochure.

As owners and operators are spending budgets and time to maintain IGBT coolant levels in open-atmosphere cooling systems, the overall cost of maintenance, replacement fluids, and reduced reliability adds up quickly. The solution our engineers designed eliminates water evaporation by containing the water vapor in a closed loop add-on system, then condensing it back into a liquid to maintain a constant water-glycol ratio maintenance to optimize the cooling system's efficiency. The results are reduced monitoring and improved turbine reliability – which net higher productivity and uninterrupted power generation and revenue streams for customers.

The KleenVent KV-CEI is part of a larger family of products designed to isolate hydraulic systems from airborne contaminants, dust, chemicals and water vapor evaporation. The KV-CEI enclosure solution works by closing off the coolant loop system from the outside atmosphere (where evaporation escapes) with a breather bladder. This bladder allows the outside air to inflate and deflate the bladder as fluid levels inside the isolation tank expand and contract due to system liquid temperature changes. A low-pressure relief valve helps prevent system over-pressurization in the case of unforeseen air trapped inside the fluid lines, and an open-close air exhausting valve allows the system to be drained and refilled quickly with the proper fluid levels during a normal preventative maintenance cycle. The current KV-CEI design is versatile enough to allow the addition of low-level liquid sensors when needed. We also can design many mounting options designed to fit a particular mounting pattern. As a testament, the KV-CEI technology is deployed in wind turbine systems for one of the world's leading wind turbine manufacturers.

The KV-CEI reservoir bladder barrier creates a closed atmosphere that expands and contracts with temperature- and atmospheric pressure-induced changes. Isolating the internal volume of the reservoir from the existing outside atmosphere prevents both evaporation of water from and the ingress of airborne contaminants into the water-glycol solution. A check valve provides over-pressure protection, and a visual level indicator allows local confirmation of the coolant level. An additional port is included to accommodate an optional, industry-standard, liquid level float switch for remote low-level coolant indication.

"Your return on investment for the KV-CEI solution can be measured in as little as a few short weeks in warmer climates and at elevated operating temperatures; meaning a quick investment in our solution can provide break-even expenditures by summer’s end, along with continued productivity savings for the life of the wind turbine."
Robert J. Marotta, product sales manager, Accumulator Cooler Division, Parker Hannifin

Ready to maximize your wind turbine's performance and improve efficiency? Our engineers' design custom, precision-engineered solutions that help even the most sophisticated wind power plants generate wind turbine energy more efficiently while improving reliability and up-time. For more detail, download ourwind turbine solutions brochure.

Learn more about wind turbine solutions and core technologies that help you harness the wind, onshore and offshore, by visiting our engineers at Windpower, booth 2286, May 23 - 25, 2017. Get a sneak peak of our featured products on demo at AWEA Windpower by visiting our wind power solutions page.

Article contributed by RJ Marotta, product sales manager, Accumulator and Cooler Division, Robert Salzer, industry market manager - wind turbines, Mark Chapman, global OEM manager, Parker Hannifin.

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You are already interested in variable speed pump drives, which save up to 70 percent energy compared to conventional drive solutions. But you are still hesitant due to their greater complexity. For you, Parker has now developed a new, innovative variation of its Drive Controlled Pump - the combination of an optimized axial piston pump with two displacement volumes and a very compact synchronous servo motor offers decisive advantages over common variable speed pump systems. 

For speed-variable applications, pumps with a constant displacement such as internal gear pumps and vane pumps are most often used. The maximum torque is always achieved at maximum pressure. This results in a high motor current for the drive system, which is determined and set by the frequency inverter. Variable pumps are a further option for adjusting the displacement of the pump, reducing the required maximum motor torque. If you want to set the displacement directly, you will need a displacement controller which is comparatively expensive. That is why Parker now offers a new variant of its PVplus axial piston pump: the dual displacement pump. The pump displacement can be switched between two continuously adjustable settings. When combined with a variable-speed drive, you get the following advantages:

• Low torque due to de-stroking in pressure holding, resulting in reduced acquisition costs for the motor and frequency converter
• High traverse speed through up-stroking when in rapid drive mode
• No discontinuity in the movement since no changeover between multiple pumps is required
• Easier pipework and commissioning
• High operating pressure, high productivity and high energy efficiency 

In combination with the Parker GVM-series synchronous motor, which is connected without a coupling or bell housing via a wave-in-shaft system to the pump, results in a very compact, dynamic unit for a wide range of applications. Drive power of up to 125 kW rated power and 400 Nm rated torque are currently available. Another build size is being developed with a peak torque of up to 800 Nm. The liquid-cooled motor can produce the same output at half or a quarter of the size of the normal IE3 motor, without any of the annoying fan noise. Due to its high heat capacity, water is especially suitable as a coolant, but you can also use mineral oil and water glycol. The permitted inlet temperature sits at up to 65°C, enabling direct cooling via the cooling circuit of the hydraulic unit.

Particularly for applications like presses, where the pressure and flow rate requirements vary greatly during the work cycle, the Drive Controlled Pump system was extended by the dual displacement pump with a liquid-cooled synchronous motor. This solution combines the capability of Parker’s axial piston pumps series PVplus with the high dynamics and power density of the GVM synchronous motor. It enables to reduce the required torque compared to fixed displacement pumps even in demanding applications and thus to design the drive system smaller and more cost-effective. The installation and commissioning of the pump used are like conventional solutions. In addition to this, no multi-variable control is required which makes operating the system easier.

Learn more about Parker’s Drive Controlled Pump and the variation with dual displacement pump and GVM motor in a detailed technical article or on our Drive Controlled Pump information page. 

Article contributed by Dr. Ing. Roland Bublitz, industrial applications engineering manager at Hydraulic Controls Division Europe in Kaarst, Germany.

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The manufacturing industry is currently facing increasing pressure to reform and innovate in order to remain viable. On the consumer side, the Internet of Things(IoT) has made smart devices available for all, and new changes and challenges of digitalisation are generating business development possibilities for industries as well. Smart IoT devices enable an industrial internet that usually includes also analytics and user action analysis. These help improve efficiency and offer new services to customers.

Parker has been actively building a new presence in industrial internet platforms and ecosystems by developing a software platform for advanced and flexible user interface design. Customised and interactive user interface applications enable machine manufacturers to increase machine functionality and efficiency and to create new types of business. Developing smart applications requires a robust software platform for the HMI (Human Machine Interface) device. The development of such HMI user interfaces also becomes more difficult, expensive and time-consuming as software becomes more complex and the amount of machine functions increases. Determining usability also requires a lot of testing and studies.

Parker’s UX Toolkit software tool enables easier development of demanding applications for machine instrumentation, control, and adjustment. The applications can include supporting applications for core machine functions, smart control systems, diagnostics or prediction applications that decrease downtime, or GPS monitoring and navigation applications. Solutions helping end users to improve performance and efficiency include applications for mobile hands-free devices, logbooks, usage monitoring, and task management (for example managing bus lines).

Application-based solutions, already commonplace on the consumer side, bring several advantages to machine manufacturers and user interface developers. These include independent development of specific applications or functions for the machine and quick launching of new features. Features can be expanded by downloading additional applications, thus offering more after-sales solutions to the customers.

We have focused on making application development as simple as possible. The UX Toolkit software is based on the open QML scripting language, and it has a WYSIWYG editor and comprehensive drag and drop functions, including:

• ready-to-use UI components
• example applications for a menu system, updates, and settings, and graphical user interface models to support the development
• quick and easy connectivity to machine control system and external actuators with ready-to-use device and protocol packages
• possibility to create user-specific settings

To ensure user-friendliness, developers can also freely modify the example applications and the appearance and use of UI components. Uniform appearance for applications is ensured by applications adhering to the Style Sheet settings of the tool. For example, a manufacturer with multiple brands can customise the graphical user interface to match each brand.

When you want to make machines more powerful and simplify cabin functions, the best choice is Parker’s Pro Display HMI display module that can be programmed with our toolkit. The machine manufacturer can centralise desired features into a single display and a uniform user interface, which decreases driver distraction.

It is very difficult for machine manufacturers to integrate functions from other manufacturers to their machine. Such functions usually have a display with its own user interface that is difficult or even impossible to integrate into an existing HMI system in a reliable way. This has been taken into account in the design of Parker’s software tool. As a result, integrating third-party system functions (such as tractor ISOBUS functions) is possible, and extra expenses of an additional display are eliminated. The certification tool of the UX Toolkit ensures that only applications approved by the machine manufacturer are installed in the display.

The UX Toolkit software is suitable for developing a customised HMI system for mobile equipment, such as:

• Agricultural equipment (tractors, combines, self-propelled machines)
• Construction machines (excavators, wheel loaders, Tower cranes)
• Special vehicles (refuse trucks, snow removals, airport equipment, road and rail applications, loaders, freight vehicles, emergency vehicles)
• Forestry machines (harvesters, forwarders)
• Materials handling machines (container handlers, mobile cranes, reach stackers)
• Public transport (buses and coaches)
• Marine (local or remote display in an engine control system)

Parker’s UX Toolkit is an excellent platform for innovative design. The flexibility of the tool allows you to create precisely the kind of product required by the machine manufacturer’s customers, and it offers a superior user experience for the machine operator.

In the era of industrial internet, mobile equipment manufacturers can use sensors to collect vast amounts of data about a machine, but they must be able to analyse and utilise the data. Pro Display has an important role in conveying and analysing the data collected by sensors and converting it into a usable format through the smart user interface applications and flexible communications connections of the display.

Visit our website for more information on Parker’s Pro Display HMI display module and UX Toolkit.

This blog was contributed by Anu Ketonen (top), product manager and Ville Karlsson (bottom), product sales manager automation & hydraulics, Mobile Hydraulic Systems Division Europe

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Are you trying to grow your business through operational excellence and by providing your customers with extended warranty? Cooling failure in hydraulic systems means automatic system shut down and unscheduled maintenance. The maintenance on cranes, ships and offshore wind turbines is extremely expensive to plan and the downtime costs money every minute. Therefore, it is important to have a supplier who can provide you with the correct technology to support your success. 

A common method of coiling and uncoiling processed steel web is center winding. Steel coilers are powered by electric variable speed drives and motors. Large motors are usually selected for coiling / uncoiling applications because of the high torque and speed demands placed on the motor. This blog explores a new technology for the steel coiling process that allows fluid power and drive system engineers to:

• Reduce motor size requirements
• Lower installation costs
• Improve coiling process efficiency
• Minimize hydraulic losses
• Operate at lower noise levels and temperatures

A fine balance between torque and speed is required throughout the coiling and uncoiling process. The coiler motor’s speed and torque change inversely proportional of one and other due to tension created by the buildup of material. As the roll builds during coiling, its circumference increases, consuming more material with each rotation. To keep up, the coiler must slow down with each added layer. The buildup of material causes the coiling arm to increase. To maintain tension, the coiler must increase torque proportional to the coil diameter. This process requires maximum torque from the motor when the coil is full, and maximum speed when at the core.

To learn how to optimize the steel coiling / uncoiling process, download this white paper.

The coiler buildup is the ratio of full coil original diameter to core/spindle original diameter.

Example: if a 72” roll has a core/spindle diameter of 24”, it has a 3:1 buildup ratio for coiling and 3:1 builddown ratio for uncoiling.

To maintain its tension, the coiler motor has to produce sufficient torque to pull the material at the necessary process tension. An electric motor transmits any remaining torque to the spindle.

To calculate the required torque, multiply the web tension by the coil radius. The required motor torque will increase proportionally to the coil buildup.

In order to maintain tension, a coil needs to match its surface speed to the incoming web speed at all times during the process. To calculate the spindle speed, divide the web speed by the coil circumference. 

During buildup, web tension and line speed are constant; therefore, the coiling power requirements remain constant and equal to the web horsepower

The motor must reduce speed inversely proportional to torque during the buildup process. As the motor slows down during buildup, its output power reduces. As a result, once the coil reaches its full diameter, the motor is only running at one third of the speed. The maximum horsepower also drops by one third.

A larger motor is needed to meet the required maximum torque and speed requirements.

Drive system engineers can reduce the required horsepower through the use of different types of electric motors. For example, by using an eight-pole 900 RPM base speed motor, its size can drop to approximately 137 HP.

There are currently many DC electric motors in use. However, they are inefficient and no longer manufactured. They are still used in many steel plants because of how difficult they are to upgrade or replace.

Hydraulic systems are known for their power density and delivery. Electric motors and variable speed drives are great for their programmability and responsiveness. The idea of combining these two technologies has been floated around by fluid power and drive system engineers for years now. Today, concerns about the higher costs of electricity and the CO2 footprint have prompted a reevaluation of these technologies. 

Advancements in new variable frequency drive (VFD) control algorithms, faster programmable VFDs, and more efficient hydraulic pumps allow fluid power and drive system engineers to successfully implement a new technology called drive controlled pumps (DCP).  

"DCP hydraulic systems are less complex and more efficient than traditional hydraulic systems. They operate at a much lower noise level and temperature, resulting in quieter and cooler surroundings."

— Rashid Aidun, application engineer, Parker Hannifin

While traditional methods of coiling use larger motors to meet the maximum torque and speed demands, DCP uses a variable ratio hydraulic transmission to keep the motor size closer to the web horsepower. 

To use DCP, the mechanical gearbox is replaced with a hydraulic pump and motor with the same displacement ratio. This produces the same speed reduction. Also, a hydraulic motor with a variable volume that offsets the buildup can be selected. A variable ratio allows the motor to run at full speed while maintaining the constant horsepower requirement. 

When the coiler runs at its minimum diameter, the hydraulic motor is set to its minimum displacement, allowing the hydraulic motor to run at its maximum speed. Essentially, when the pump runs at a smaller displacement, it produces a lower torque and a higher speed, making the process more efficient. 

DCP technology combines the best features of electrical and hydraulic systems to optimize the coiling and uncoiling process resulting in:

• Smaller motor requirement
• Reduced electric and drive system and installation costs
• Low heat generation
• Improved operating efficiency
• Minimal hydraulic losses
• Fewer, less complicated hydraulic valves
• Lower noise levels

To learn more about the theory behind DCP technology and how it improves coiling and uncoiling process efficiency, download this white paper.

This blog was contributed by Rashid Aidun, application engineer, Parker Hannifin.

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As hydraulic systems on construction equipment continue to evolve, the goal of increasing simplicity, reliability and productivity remains the same. Parker Variable Flow Open-Center (VFO) takes a big step towards realizing these objectives.

The most common hydraulic systems on mobile equipment are based on two designs: an open-center valve technology with fixed displacement pumps or load-sensing (LS) valve technology with variable or fixed displacement pumps. Both of these arrangements have their benefits. The open-center system, for example, is simple, cost-effective and provides the operator with a less jarring operation.

VFO innovatively employs a variable displacement pump controlled by an open-center type valve. The result: VFO integrates the advantages of the current technologies (simplicity, cost-effectiveness, smooth operation) with the energy efficiency of piston pumps.

The distinct value of the variable flow open-center system can be seen from several perspectives:

Simplicity: There are no compensators and shuttle networks (open-center valve technology).

Reliability: In general, less complexity means more dependability (open-center valve technology).

Productivity: The system optimizes the energy balance of variable-pump technology.

Applicability: It can work with any valve control type without the need for electronics.

Parker is a global leader in motion and control technologies and a pioneer in the variable flow open-center system.

For in-depth details on our VFO, download the white paper.  And for additional construction equipment content from Parker, visit www.parker.com/buildingbetterlives. 

Article contributed by Germano Franzoni, Ph.D., senior systems engineer, Parker Hannifin, Global Mobile Systems.

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For increased simplicity, reliability and energy savings from your wheel loader, consider the proven results of split pump Intelligent Flow Control (IFC) architecture. 

For the most part, wheel loaders are currently employing a system featuring load-sensing technology, the main functions being steering and implement control.  This system can utilize a single pump for both functions or two pumps.  While this architecture has been practical, it can now be surpassed.

The Parker Global Mobile Systems team created an innovative concept that reduces system complexity while increasing efficiency and performance.  The system uses two electric displacement controlled pumps and an electronically controlled open center valve with three sections.  Now, each function can use full flow from both pumps during a single function operation, and a dedicated pump during multi-function operations for optimal energy balance. 

In tests, the split pump IFC system used 24% less hydraulic energy compared to the baseline load-sensing system.  In fuel consumption, this translates to fuel savings of 1.8 gallons per day, which could save $900 yearly per vehicle.

Simplified architecture– using open center valves with an electronic displacement control pump reduces failure points, leak paths and cost.

Reduced energy losses– by controlling flow to specific functions, losses through the valve are minimized.

Improved response time– by using an electric control pump, the time from operator input to pump stroking is reduced.

Parker is a global leader in motion and control technologies and the creator of split pump Intelligent Flow Control (IFC) architecture.

For in-depth details on Split Pump IFC, download the white paper.  And for additional construction equipment content from Parker, visit www.parker.com/buildingbetterlives. 

Article contributed by David Schulte, systems engineer, Parker Hannifin Corporation, Global Mobile Systems.

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Looking to improve the efficiency of your construction equipment? Consider a hydraulic fan drive. Compared to mechanically driven fans, hydraulic fan drives provide several advantages. This is proven across multiple markets and applications.

Because most vehicles already have a hydraulic system in place, it’s easy to switch to hydraulic fan drives. Once in place, the fan can be decoupled from the engine speed so no excess cooling is generated. The fan can now run at the necessary speed regardless of engine speed. This creates amazing efficiencies: total overall efficiency gained can range from 70% - 90% depending on the system.

One critical efficiency is in fuel savings. Compared to a mechanical drive, a hydraulic fan drive system can save one gallon of fuel per day. This can amount to $600 in savings per vehicle per year (based on $3.00 per gallon diesel fuel and 200 work days per year).

Another area of efficiency is in power consumption. Because the fan drive is consuming less power, it allows for the freed up power to be employed doing useful work. The result: a more productive vehicle.

Additional benefits include the ability to control the engine temperature. By using temperature sensors, highs and lows can be set, turning the fan on and off accordingly. Hydraulic fans also have the ability to reverse motion, which can clean radiators by blowing the dirt and debris out. And hydraulic fans can be mounted remotely, freeing up space for other components.

Lastly, but importantly, hydraulic fan drives are vital to complying with Tier IV emissions regulations. That’s the true power of hydraulic fan drives. Parker is a global leader in motion and control technologies and a pioneer in hydraulic fan drives.

For in-depth details on hydraulic fan drive options, download the white paper.  For additional construction equipment content from Parker, visit www.parker.com/buildingbetterlives.  

Article contributed by Andrew De Jong, engineer, Parker Hannifin Corporation, Global Mobile Systems.

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Dump pumps have long been the standard in the dump truck and trailer segment. The cost-effectiveness of a combination pump and valve with a built-in relief has been a winning combination in the North American marketplace for decades. 

Trucks are constantly evolving and space for hydraulics has become a major issue. In today’s fast-paced world, the dump body lifting speed requirements are increasing. As a result, most fleets require pumps with larger volumetric displacements and that presents a problem - there’s often no room left next to the truck's transmission for a larger pump with a built-in valve. Newer trucks have more exhaust piping, DEF tanks, diesel particulate filters, SCR catalysts, tighter frame rails, heat shields and several other obstructions that just weren’t an issue 10 years ago.

Using a smaller combination pump and valve, for example, Parker’s G101/102 Series dump pumps, won’t deliver the same dump body lifting speed performance. Now, there’s another option that has entered the market.

Our CVA16 tipper valve can be used with the PGP051/PGP350 series gear pumps and with most fixed displacement hydraulic pumps. Unlike traditional valves, this valve can be placed anywhere along the chassis of the truck, helping to eliminate spatial constraints. 

For such a small component, the benefits are substantial. In addition to solving the problem of space, the CVA16 tipper valve is:

• extremely cost-effective - the tipper valve should last the life of your truck;

• very robust and not overly sensitive to contamination;

• easy to install and the only one on the market today that comes with an owner's manual and installation guide;

• available for purchase from any Parker Distributor that carries gear pumps;

• available as single or dual pressure, with cable and air shift options; 

• three different in-cab console options to pair with the valves;

• easy to plumb.

The air shift version comes standard with a ¼” SAE DOT push-to-connect fitting.

You can use this version of the valve to operate systems requiring two different pressure settings. The low-pressure setting can be used for a dump hoist and the high-pressure setting can be used for a moving floor or another circuit requiring higher pressures.

In today's rapidly evolving world where taking chances could mean not getting the job done, Parker is there with the tools to make maintaining your truck easy. If your work trucks demand a high-displacement dump pump but don't have space for one, the CVA16 tipper valve series is a cost-effective solution.

Download the brochure or owner's manual for specs and installation guide for more information.

Article contributed by Nicholas Roberto, national sales manager, Vocational Truck Team, Parker Hannifin.

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2017 brought about innovative new technologies that laid the foundation for the latest hydraulic systems and applications designed for construction, agriculture, mining, power generation and related markets. From smart user interfaces to load sensing valve technology to hybrid actuation systems for renewable energy applications and more, the solutions revealed in these blogs have customers documenting productivity increases, energy savings and maximized operational efficiency - both at the plant and on the job site. Learn about the key technology trends that shaped the most read hydraulics blogs in 2017.

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The manufacturing industry is currently facing increasing pressure to reform and innovate to remain viable. On the consumer side, the Internet of Things (IoT) has made smart devices available for all, and new changes and challenges of digitalisation are generating business development possibilities for industries as well. Smart IoT devices enable an industrial internet that includes analytics and user action analysis. These improve efficiency and offer new services to customers. Parker has been actively building a new presence in industrial internet platforms and ecosystems by developing a software platform for advanced and flexible user interface design.

Modern industrial machinery is creating ever-increasing demands on hydraulics to provide more efficient and quieter solutions with a smaller footprint, while maintaining the benefits traditionally associated with hydraulic systems, i.e., high power density, precise control and enduring performance. But historically, these benefits have come with the high cost of inefficient energy allocation, heat generation, and noise. The variety of discreet components constituting each hydraulic system has complicated the challenge.

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New Hybrid Actuation System Ideal for Renewable Energy Applications

Actuation systems must be efficient, precise, and durable enough to withstand harsh power generation environments. Parker Hannifin 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 hydroelectric dams.

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Looking for ways to reduce worker compensation claims and improve route times, among other benefits, some municipalities and waste companies look to design changes from the refuse truck OEMs to assist. Parker's rotary actuators engineered for use on waste-receptacle dumpers have delivered.

A Midwest-based original equipment manufacturer (OEM) designs and builds waste-receptacle dumpers that attach to garbage trucks, recycling vehicles and other waste-handling equipment. The lifter attaches to the front or side of a vehicle or onto the dumpster of a front-load refuse truck. After an operator positions a receptacle cart onto the dumper, the latter then lifts and tilts the cart, spilling its contents into the vehicle. When the dumping cycle is complete, the lifter returns to a stowed position.

Advantages of using carts and cart lifters include reduced worker compensation claims, faster route times and larger routes since workers don’t tire as quickly. The carts also improve street sanitation, reducing health risks by helping prevent animals from disturbing waste left outside overnight.

The helical rotary actuator (painted black shown with arrows) provides 220 deg. of rotation, completely emptying carts.

The heart of the lifter mechanism is a helical rotary actuator—a TorqBear Series Model T20-14E, manufactured by Parker Helac, Enumclaw, Wash. The 220 deg. of rotation produces a sharp and aggressive dumping angle that completely empties the contents of the cart.

The actuator’s mounting feet with through drilled holes facilitate attachment to the lifter mounting plate: The feet are not flush with the actuator housing but, instead, are situated on the sides of the housing. This contributes to the compact nature of the mechanism by enabling the actuator to be positioned partially below the surface of the mounting plate. The through-shaft has extensions at both ends with straight spines that facilitate the easy attachment of the lifting arms—adapters with matching splines to which the arms are welded.

These sectional drawings show the operation of a helical-gear rotatory actuator.

The use of the actuator in its lifter designs allows the OEM to build a high-performance machine not possible with a cylinder. Actuator-equipped machines dump higher and deeper than cylinder machines. At the same time, they can be designed thinner, making access to the hopper by the operator as easy as possible.

In the illustration, the cutaway shows initial positions of piston (green line) and output shaft (red line). Pressurized fluid entering the lower port pushes the piston up. The stationary ring gear causes the piston to simultaneously rotate clockwise. In the cutaway at right, teeth on the output shaft mesh with those in the ID of the piston, causing the shaft to rotate clockwise relative to the piston. (The output shaft rotates at twice the speed of the piston.) Pressurizing the upper port returns the piston and shaft to their initial positions.

The long, slender configuration of the helical shaft actuators provides a clean, compact design that enables the lifter mechanism to be bolt mounted flush to the vehicle for an exceptionally low profile. The rotary actuator has no exposed moving parts; lifters using hydraulic cylinders can provide no more than 180 deg. of rotation and incorporate a more complicated system consisting of bearings, brackets, pivot points, and rods—all exposed to damage. Further, the inherent characteristics of Helac’s helical rotary actuators offer several advantages over other rotational devices and actuator designs:

Very high torque output in an ultra-compact configuration; Equal torque output from both ends of the shaft; Shaft support provided by integral large diameter tapered roller bearings; Smooth, positive positioning without drift due to the elimination of internal bypass and external leakage (and nearly zero backlash); No exposed, external moving parts; A helical gear design that provides exceptional resilience to shock loading and abuse; Constant speed and consistent torque through the entire angle of rotation; and much cleaner and more streamlined installation.

Taking everything into account, the helical actuators have enabled the refuse truck OEM to design a compact lifter with power sufficient to lift heavily loaded carts.

A typical refuse truck’s hydraulic system operates at pressures to about 3,000 psi, with flow rates varying widely from 20 to 80 gpm. The rotary lifter uses less than 2 gpm, so a way to siphon off the correct flow was required. The lifters tap into the truck’s existing pressure line via a flow-diverter valve. This custom-made valve sends an adjustable amount of flow to the lifters and allows the remaining flow to pass through to the packer (compactor) blade.

The system has been designed to minimize back pressure, which in turn, minimizes heat and extends oil and system life. Competing OEMs use a fitting with an orifice, but those systems do not properly regulate flow (which fails to regulate lifter speed) and create excess heat. The Helac actuator has been designed for low flow requirements, thus helping minimize oil take-off from the packer and virtually eliminating any packer slow-down.

This article originally appeared on Hydraulics & Pneumatics and was contributed by Jessica Howisey, marketing communications manager, Helac Business Unit, Cylinder Division.

Given the many risks of excess heat in a hydraulic system – such as fluid decomposition, increased wear on system components, damage to seals and bearings, etc. – the need for an effective heat exchanger is often an essential consideration.

Smaller hydraulic systems with low operating temperatures may be able to rely on natural convection, but when that doesn’t provide sufficient cooling, a heat exchanger must be installed. You can also assume a heat exchanger is needed when a specific oil temperature is required to stabilize hydraulic fluid viscosity, or when equipment has a history of hot oil problems, such as shortened seal life or frequent oil breakdown.

Whether you work with large mobile equipment (for example, construction, military, forestry, and material-handling units) or commercial/industrial process machinery with hydraulic systems, hot fluid is a concern. A properly sized heat exchanger in any equipment can save time, money, repair headaches and extend system life.

To learn more about heat exchanger types and choosing the proper size for your hydraulic system, download the whitepaper. 

So how do you determine which heat exchanger is best for a particular application? As with most design challenges, the answer is, it depends.

Accurately defining hydraulic cooling needs can be confusing because actual heat generation often varies as a machine goes through different cycles and because ambient temperatures or other environmental factors can affect system heat levels. When considering application and sizing of heat exchangers, the ideal operating temperature of the hydraulic fluid and the time it takes to arrive at that temperature must be used.

“There are many factors to consider and a wide range of heat exchangers, with certain benefits to each kind. The choice of a heat exchanger generally ties directly to the type of system to be cooled. That means you have to take into account vital parameters like heat load, available space, environmental conditions, power source, noise, operating costs, and so on.”
Rick Morton, business development manager, Parker Accumulator and Cooler Division.

Whether it’s a new design or a retrofit, it’s hard to pick the right heat exchanger without identifying the challenges and performing all the calculations. Fortunately, most heat exchanger manufacturers offer software to help you determine the best fit for each application. For example, we provide an online calculator (Essential Cooler Sizing Parameters) and other interactive resources where an engineer can plug in specifications to get a better idea of what exactly is needed.

Given the many variables involved, it’s not uncommon for some engineers to delay their decisions on heat exchanger specifications until after seeing how a system performs and how much heat transfer is actually needed.

When you have questions, it's often best to simply contact a heat exchanger supplier directly. Here at Parker, if a customer comes to us with questions on heat exchanger specifying, we can walk them through the process.

Before reaching out to a manufacturer for assistance, a bit of preparation will go a long way in expediting the selection process. For example, gathering the necessary information such as heat load parameters and other key influencing factors. 

To learn more about heat exchanger types and choosing the proper size for your hydraulic system, download the whitepaper. 

Article contributed by Rick Morton, business development manager, Parker Accumulator and Cooler Division.

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Inefficient energy allocation, heat generation and noise are typical concerns among facility engineers in manufacturing environments. Parker’s new variable speed drive solution, called Drive Controlled Pump (DCP), increases hydraulic power unit efficiency while maintaining high power density, precise control and performance. DCP is the pairing of electric motors, hydraulic pumps, electronic drives and software to meet the local load demands within your hydraulic system. Precisely controlled variable speed pump macros are custom configured to meet the functional requirements of each process within a complex hydraulic system. 

Don’t just use the Hydraulic Power Equation to size the electric motor.

(HP = P x Q ÷ 1714)

Do compute the pump torque first, then use the motor’s base speed to compute power.

(T = Vi x P ÷ 24π)

(HP = T x N ÷ 5252). HP: Horse Power, P: Pressure PSI, Q: Flow GPM, T: Torque Ft-Lb, Vi: Pump Displacement In³/Rev, N: motor base speed (4 pole motor’s base speed = 1,800 RPM).

Don’t just use load’s flow and pressure demand to compute motor power.
Do consider the pump’s internal flow and torque losses at various speeds and pressures.

Don’t be content with power computations to maintain flow and pressure.
Do allow for the acceleration power requirement. Variable speed pump controls need reserved power to accelerate the combination of the electric motor rotor, couplings and the pump’s rotating group while under full pressure. The reserved power gets larger with the acceleration rate and rotor moment of inertia.

Ta = I x Δω / (308 x Δt), Ta: Acceleration Torque(Ft-Lb), I moment of inertia (LB-Ft2), Δω: Speed Change (RPM), Δt: Speed Change (Sec)

Don’t oversize the electric motor. Oversized motors have larger rotor inertia and require larger drives to power.
Do break down the cycle by pressure, flow and time. Compute each segment for power.

Don’t just use maximum flow and maximum pressure to compute power. You might end up with an oversized motor.
Do use the larger of the two computed horsepower values. Compare flow at maximum pressure and pressure at maximum flow.

Don’t just use the RMS value of computed power segments to size the electric motor.
Do use the RMS value, yet pay attention to peak power. Peak power should be less than 150% of the selected motor size, and its duty cycle must be within the operation parameters of the electric motor and drive.

Don’t use your standard TENV electric motor for variable speed fixed pumps.
Do use low rotor inertia motors to minimize reserve acceleration power. Open frame and force ventilated motors offer much lower rotor inertia.

Don’t exceed the induction motor’s base frequency when operating at maximum pressure.
Do exceed motor’s base frequency only when pressure drops proportional to over-speed.

Don’t operate below the minimum recommended pump speed. Operating below minimum speed damages the pump.
Do add a controlled bleed off loop to the pump’s outlet to limit its minimum speed. Also, an accumulator can allow the pump to get turned off at deadhead conditions.

Don’t accelerate/decelerate a pump too fast.
Do limit the pump speed change rate to stay above the pump’s minimum inlet pressure to avoid cavitation. Also, keep in mind rapid pump speed changes consume additional power which can lower the HPU’s efficiency.

To learn more about Drive Controlled Pump (DCP) Technology, download the white paper, Integrated Energy-Saving Hydraulic Systems Customized to Your Application Requirements here or view the on-demand presentation.

Rashid S. Aidun who draws on his electrical and fluid power background to create custom drive controlled pump solutions. Prior to joining Parker 17 years ago, he worked as an industrial manufacturing and fluid power and controls engineer for various OEMs. He has a BSME from Syracuse University.

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