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.

Improve Steel Coiling Process Efficiency With DCP

Energy-Saving Hydraulic Systems Using Drive Controlled Pump (DCP)

Proportional valves that employ powerful, voice-coil valve technology are used in applications where higher flows from smaller valves are ideal. While the list is endless, a few of the activities in which you may need to use these particular valves are lifting, steering and suspension. For an improved operation, acting on these three tips may be in your favor.

Trapped airflow is a common problem for proportional valve systems. When it comes to pilot operated valves, it can take some time to get the air out. Some indicators of trapped airflow due to valve instability include pulsing, modulation or an unusual performance overall. Higher flows tend to help push out the trapped air behind the spool so if you can run yours at a higher flow, then it should perform well at lower flows. 

The position of your valve plays a big role in the operation. Be sure that the valve is not positioned at the high point of your system or in an upright orientation. This can trap the air. Keep the valve mounted horizontally so the tube is off to the side. An advantage to having the tube horizontal is that any G load acting on the valve will not tend to self-activate the valve. Some systems see about 3 to 5 G loads but can go as high as 10 G.

Ideally, the proportional valve is located below the oil reservoir with the tank port of the valve oriented upward. This keeps the oil in the valve when the system is shut down. On many systems, we have used a check valve in the tank line to help with this and have seen this help with stability in several cases.

For our proportional valves, we call out a specific PWM frequency for best results on these products. Some operators may not be following this and could be using IQAN or something similar. However, we do not have any test results for this type of system. Keep in mind that the dither frequency and amplitude are different from each manufacturer but drivers typically range anywhere from 1 kHz to 10 kHz. 

To achieve the best possible operation, users should follow the manufacturer’s operational guidelines. Find out more about Parker's proportional valve offering from the Hydraulic Cartridge System  Division.

Parker offers a wide range of proportional valves that employ a powerful voice-coil valve technology through its Hydraulic Cartridge Systems Division. Visit the website or consult your Hydraulic Cartridge System Division Catalog for more information.

Article contributed by Stephen Brunton, product manager, Hydraulic Cartridge  Systems Division.

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The advancements in hydraulics and variable speed drives (VSD) were running in parallel for many years but on opposite sides of the fence from each other in solving paper converting industrial applications. Once the engineers on both sides met in the middle and shared their knowledge, a door opened to a new way of thinking and problem-solving. Combining VSD and hydraulics was difficult at first; the unforgiving nature of positive displacement pumps, the non-compressibility (incompressibility) of the fluids, demanded a different solution than what VSD engineers had experienced with more forgiving lower pressure centrifugal pumps. The combination of hydraulics and VSD has created a new type of system with lower noise, fewer components, and higher energy efficiencies. 

Download our white paper and learn how Drive Controlled Pump (DCP) technology can make center winders the ideal winding technology for the paper converting industry.

Hydraulic systems are known for their ability to deliver significant power density in a small package. Electric motors and variable speed drives are known for their programmability and responsiveness. Dating back to the 1990s, hydraulic and drive system engineers could see the potential for combining the two technologies. Historically, the motion control industry has had limited success in combining the technologies. However, in today’s manufacturing environment, the higher cost of electrical power, the increasing global concern for the CO2 footprint and the need for quieter industrial solutions offer opportunities to reevaluate the combined technology. Today, the advancement in new Variable Frequency Drives (VFD) control algorithms, faster programmable VFDs and more efficient hydraulic pumps specifically designed for variable speed applications allows our engineers from both technologies to work together with greater opportunities for success by implementing an ideal technology known as Drive Controlled Pump technology (DCP).

Traditionally, electromechanical drive systems are used for the majority of converting line’s center winders or combined center surface winders. These drive systems use electric motors larger than the web horsepower by the factor of their buildup ratio. DCP can keep the electric motor size close to its web horsepower by eliminating the buildup factor in a winding application. This takes advantage of the continuously variable flow and pressure feature of an electronically controlled variable displacement hydraulic pump operating at variable radial speeds.

Taking advantage of electric drive and hydraulic technology yields a positive outcome in winding and unwinding techniques. DCP technology allows us to create a wide constant HP range and trade speed for torque during the buildup process while reducing the size requirements for the electric motor. Since this technology operates the hydraulic pump at a variable speed; it uses fewer and simpler hydraulic valves. DCP hydraulic systems are less complex and more efficient than traditional hydraulic systems; it operates at much lower noise and temperatures resulting in quieter and cooler surroundings.

This system is very flexible; a variable displacement motor and a fixed displacement pump can be used to achieve the same results. The following diagrams show the control schematic of a DCP winding system using a variable displacement hydraulic motor and a fixed displacement open loop pump.

The system can also be adapted to closed loopX hydraulics and unwinding applications quite easily as shown below.

Paper converting lines employ surface, center, and center/surface combination winders and each winding technique has inherent benefits and limitations. Download our white paper and learn more about how Drive Controlled Pump (DCP) technology can make center winders the ideal winding technology for the paper converting industry.

Article contributed by Rashid Aidun, application engineer, Parker Hannifin.

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Control of vehicle speed is important to equipment operators. The ability to accurately set the speed of a conveyor or roller in applications such as road paving or striping, crop sprayers and sugar cane harvesters is essential to help optimize productivity and help reduce waste. Additionally, the ability to enter a user ID, PIN or password is often a requirement to help ensure only authorized users have access to operate heavy equipment. Although large, more complex displays can perform these basic functions, they are often not cost effective or small enough to be a good application fit.

The PHD28 touch screen display offers a cost-effective replacement for a traditional, robust keypad in a dynamically configurable platform. In addition, the PHD28 has enough built in processing power to perform basic calculations, check entry limits of values entered, rescale values or even change the value based on an incoming CAN message or input signal. With its compact, 2.8-inch size, it fits well in many consoles and dashboards without compromising valuable space. PHD28 used in conjunction with other Parker electronic products creates a simple to use number entry system that can control complicated systems.

When control of conveyor speed is needed to perform the functions of the vehicle, a PHD along with an IQAN controller can provide this functionality as a low cost and efficient solution.

For example, the PHD28 programmed as a numeric keypad will allow the operator to select the desired conveyor speed and then transmit that value to an IQAN MC43 controller to control the vehicle.  This instance can be expanded to any of the PHD family displays as well as the IQAN family of controllers.

In this example, a value is entered by the user and if within range, the target speed is transmitted over the CAN bus to the IQAN controller.  To confirm the value, the feedback from the IQAN controller is shown in the top right of the screen and is used to control the vehicle speed. 

The IQAN controller can then communicate with the diesel engine and brake control system to regulate vehicle speed.  When vehicle speed does not match the input value from the keypad, the IQAN controller can notify the engine to speed up if the vehicle is moving too slow.  If the vehicle is moving too fast, the IQAN controller can activate the brake system so the vehicle will slow down. 

Vehicle speed can be measured using a sensor such as a Parker GS60 speed sensor.  The frequency output from the GS60 can be connected to the IQAN controller, which would use a PID loop to control the engine and braking system to maintain the desired speed.

If an operator must adjust vehicle speed, they can enter the appropriate speed value or use the up and down arrows to adjust the current value. 

Parker offers the keypad program for the PHD eliminating the need for programming in this specific configuration.  An IQAN 5 external function and example application is also supplied to make it easy to integrate with the rest of the IQAN application. If a custom design or look is desired, the PHD28 can be programmed to fit that application using Crank Storyboard software.

In the example to the right, the screen shows a numerical keypad where the user can enter a numerical value with 0.1 precision.  The user enters the value and then has the option to select cancel, revert to the previous value, or enter to accept the value.  Upon acceptance, the value is then transmitted to the system controller via a J1939 message.  The user also has the option to increment and decrement the current value using the up and down arrows.

This example is configured so that the system controller can send an acceptable maximum value as a variable to the PHD to qualify the input value is within range.  Then the PHD gives a color coded visual indication to the user the value was accepted.In the example above, the screen shows a numerical keypad where the user can enter a numerical value with 0.1 precision.  The user enters the value and then has the option to select cancel, revert to the previous value, or enter to accept the value.  Upon acceptance, the value is then transmitted to the system controller via a J1939 message.  The user also has the option to increment and decrement the current value using the up and down arrows.

The transmitted J1939 message in this example uses PGN 0xFF00 with two parameters: the entered value and a Boolean search that is active while the OK button is pressed.  The resulting J1939 message in the example also uses PGN 0xFF00 with two parameters:  the maximum acceptable value and a feedback value so the system controller can acknowledge that entered value was accepted.

This application example can be used as is for a basic keypad device, can be modified to accommodate desired form and function or can be used in an existing PHD application to add keypad functionality.  The example contains the graphical content, screen layout using Crank Storyboard and functionality written in Lua script.

In many cases, the content of the keypad should be adjusted for regional content, customer color theme or operating mode. These dynamic changes cannot be accomplished on a traditional mechanical keypad.

  Product

  Features

  PHD28 Display

  Easily enter and change values in system

  IQAN-MC4x Controller

  PHD program and IQAN function group available

  GS60 Speed Sensor

  Robust, outdoor rated products

To learn more about PHD Displays, view our product literature, technical specifications and reference materials.   

Article contributed by Edward Polzin, regional application engineer - central, Electronic Controls Division, Parker Hannifin Corporation

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Most people enjoy theme parks as a place to get away from work, but for those in the hydraulics industry, they are a place to demonstrate their expertise. Behind many of the rides that make your stomach drop or your eyes blink in amazement, Parker's accumulators are picking up the stresses and enhancing the performances of hydraulic technology.

Behind the scenes, there is complex machinery that must run precisely and smoothly to ensure safe and reliable operation. Whether you are splashing through water, sailing above the tree lines, or being wowed by animations and simulations, powerful equipment that depends on the science and engineering of hydraulics is enriching your activities.  And, many of these large, powerful hydraulic systems rely on accumulators; hidden from the public view, but critical in their roles.      

Typically, accumulators installed in hydraulic systems store energy to either provide an extra boost of power or absorb energy to smooth out pulsations. One of the world's largest manufacturer of accumulators is Parker's Accumulator and Cooler Division. According to Jeff Sage, product sales manager, the Parker accumulators used in theme parks are gas-charged and are either bladder accumulators or piston accumulators. Parker manufactures both types and has the engineering expertise to recommend which kind best fits the requirements of a particular ride.

Bladder accumulators are cylinders that contain a rubber bladder (Figure 1). Hydraulic oil is kept under pressure when the bladder is inflated with an inert compressed gas, often nitrogen. When a ride needs a quick burst of power, a valve opens and releases the pressurized hydraulic fluid.
 

Piston accumulators are metal tubes with an enclosed piston(Figure 2). One side of the piston is charged with a pressurized gas and the other side with hydraulic oil. When the ride requires additional power, the pressurized gas pushes against the piston which forces hydraulic oil back into the ride’s power unit.

Watch it in action:

Accumulators often play valuable roles in hydraulic systems that power rides for a variety of reasons. As you can imagine, moving multi-ton cars, coasters, and props, often times with rapid acceleration in minimal time, requires extreme bursts of force. Delivering this concentrated force is taxing on hydraulics systems and can cause jerky movements. Accumulators work to absorb these extreme pressures and movements, store energy and keep performance consistent – delivering the extra “push” when a hydraulics system needs it.

Often there are many accumulators used on each ride. For example, on motion-simulator rides, which have become quite popular since the 1980s, many accumulators are used. These are amazing rides where people feel all the shakes, rattles and rolls depicted in a movie shown on a large screen. A big surge of energy is needed to move the platform. Within these rides there are 24 platforms, each with banks of 10-gallon bladder accumulators. Each time the platform moves, a quick burst of energy is needed. These accumulators provide the high acceleration needed to make the ride exciting and memorable.

Safety, of course, must be at the forefront of manufacturing accumulators. A ride that breaks down can cause injuries or worse. Most bladder accumulator failures come from the bladder failing. Parker accumulators minimize the issue by manufacturing its own bladders for quality control reasons. This is not common and differentiates Parker from the competition.

Knowing how important the chemical process is in the making of these bladders, the company has its own chemist, buys the rubber and mixes the bladder compounds. With everything controlled and created in-house, this helps Parker produce accumulator bladders that are of the highest quality and reliability.

And when a piston accumulator fails it is typically a result of a leak in the rubber seal located on the outer cylinder of the piston. A proper functioning seal separates the gas from the oil. Gas molecules are very small and can penetrate through the rubber seal. Parker applies its expertise in rubber composition to develop seals that minimize the gas permeation, thus extending the life of the piston accumulator.

Nothing stops the fun at a theme park like a sign at a ride’s entrance that says, “OUT OF ORDER.”

Carlos Aguirre, a Sales and Systems engineer at Bernell Hydraulics Inc., uses Parker because of their accumulator expertise, reliability, and service. Bernell and Aguirre have a long history of working with the nation’s top theme parks and using Parker's accumulators to keep the attractions running smoothly and safely. Aguirre and his teams work overnight after theme parks close, so it’s essential that he chooses trusted vendor partners that can deliver dependable parts when they are needed. While most of Aguirre’s theme park projects have used bladder accumulators, new projects are requiring piston accumulators. 

“Park patrons want to enjoy their favorite rides. I need quality parts delivered on time so we can get the work done at night and have the ride ready to roll when the gates open in the morning. I like the expertise Parker offers on either type. One call and I get the information I need to make theme parks fun and safe for all.”

Carlos Aguirre, sales and systems engineer at Bernell Hydraulics Inc.

The next time you’re at a theme park waiting to ride, we hope that the greatest energy is the energy of the moment. However, you might take a moment to appreciate the extreme amounts of force and energy required for your favorite ride to give you a hair-raising experience. For our accumulators, handling the exciting extremes is a walk in the park.

If you would like more information about accumulators, visit Parker Accumulator and Cooler Division.

 Article contributed by Jeff Sage, product sales manager, Parker Hannifin Accumulator and Cooler Division.

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The ability to see behind a machine and work area is crucial to improve safety in the operation of heavy equipment and machinery. Just as in automobiles, the capability to see behind a mine haul truck, forklift, reach stacker or other machinery is important when maneuvering. Additionally, the ability to see the work area including the fork placement on a forklift, grain conveyor on a harvester or the top hatch on a refuse side loader truck is also important for safety and to help improve operator productivity. Having a camera in place to see if the conveyor is clogged or if the top hatch is blocked can help reduce time, as well as allowing the operator to see potentially dangerous or damaging conditions before they become critical.

More and more heavy equipment, construction machinery, specialty trucks and agriculture equipment are using operator displays in the cab to improve the machine interface. Although dedicated video screens are readily available, having an additional screen for just video, adds cost and can inhibit the operator’s visibility. The ability to integrate video signals onto screens offers a cost-effective solution, as well as improving operator visibility by reducing the number of screens in the cab.

The PHD50 and the PHD70 touchscreen displays offer the ability to not only perform the operator interface for engine and machine diagnostics, status and configuration, they also support video input directly to the screens. The PHD50 supports a single video feed, while the PHD70 support two video feeds.

Both PHD models can perform logic and calculations to allow the video screen to show dynamically, based on events or fault conditions. For example, if the loading arms on a refuse truck are raised, but the top hatch is closed, the top hatch video camera feed can automatically appear on the screen to inform the operator of the condition. When a mine haul truck is put into reverse travel, the backup camera feed can automatically appear, or if the chipping wheel on a whole tree chipper signals an overload, the workspace camera can automatically appear to show the operator what is causing the overload. This can dramatically improve the machine efficiency by allowing the operator to proactively deal with possible dangerous or work stopping conditions.

In this example, the PHD50_Camera.zip and PHD70 Camera.zip files include an example application program that shows how to implement the single video input into the PHD50 and both video inputs into the PHD70. In addition to the video input(s), the example has implemented the following features:

• Flip the video screen for backup camera orientation.

• Backlight adjustment with Auto Backlight for night and day operation.

• Selection button to select video 1 or 2 on the PHD70.

• Entering sleep mode and using a screen touch as a wake signal for power saving operation.

• This example uses an NTSC analog camera, but PAL is also supported for broader market opportunities around the world.

This application example can be used as is for basic video screens or can be modified or included in another PHD application to incorporate the advantages of video screens into an application to accompany engine and machine parameter settings, showing fault codes and overall status and gauges. The example contains the graphical content for the video feed selection, the script to invert the video image and the screen to set the back-light intensity using Crank Storyboard and functionality written in Lua script.

To learn more about how PHD displays can help equipment operators, view our product literature, technical specifications and reference materials.

Article contributed by Edward Polzin, regional application engineer - central, 
Electronic Controls Division, Parker Hannifin Corporation.

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Over the last several years, the trend in the oil and gas market has been the near constant decrease in oil prices. As prices continue to drop, companies must find ways to remain profitable by streamlining costs. Design engineers are continually seeking more efficient technologies that can provide the same production capabilities while lowering the cost of operation.

Parker axial piston pumps provide a new-found efficiency. The P1 and PD Series Pumps are a step above the competition because of their energy recovery feature. This feature greatly reduces energy expenditure which saves cost. The pumps are designed to function as a pump to raise the rod string, then as the rod string gravity lowers, the pump is designed to go over center and work as a motor to recover the kinetic energy, which can then be used when raising the rod string or putting the energy back to the grid. In addition, this design allows the pumps to meet duty cycle requirements in applications where competitive products cannot accomplish this.

The P1 and PD series also have exceptional bearing life, which allows it to last longer than competitive product. This reduces down-time and the total cost of ownership. In an industry where down time is extremely costly and operating costs are critical, this feature is invaluable.

The P1 and PD medium pressure axial piston pumps utilize electronic control systems to optimize performance with the ability to work with their own ECU or directly with the machine or vehicle’s ECU. The pumps ECU even feature a CANbus interface to support whole-vehicle CANbus systems.

Besides electronic controls, the P1 and PD series offer a broad range of controls, including load sensing capabilities. In oil and gas applications where there can be wide fluctuations in flow and pressure, load sensing controls can save considerable amounts of input power. A load-sensing controlled variable pump eliminates most inefficiencies created by fixed displacement pumps. This reduces the amount of energy lost when the pump is not operating at maximum flow and electronic controls just take that one step further minimizing losses even more than a load sense control.

As the public continues to demand a lower dependence on foreign sources of oil, companies are hastily trying to find domestic reserves in commercial quantities. This has forced companies to look for and produce oil and natural gas in locations previously thought to be too close to residential and commercial areas, greatly increasing the need for low-noise equipment due to regulations of operating in such areas.

The unique design of the P1 and PD allow them to excel in low-noise applications. They provide exceptional motor function, while leading the competition in noise reduction. They provide such low noise output that they can be used in a wide array of new low noise applications that have never been tapped due to limitations of other products, while still being cost competitive and highly efficient.

P1 and PD Piston Pumps are now available for purchase on parker.com. Simply add products to your cart for shipment from a Parker Distributor.

Article contributed by Keith McDonald, product manager, Hydraulic Pump and Power Systems Division, Parker Hannifin Corporation.

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Chvalis is an expert on delivering turnkey solutions according to rail manufacturer's specifications, including delivery, installation and commissioning. Chvalis has been using Parker's products since 1992 in its systems for their unmatched quality, reliability and security. Components also meet the most demanding certifications. In the railway industry, Chvalis is the holder of the Certification of Technical Competence of the Czech Railways supplier and the SŽDC Supplier's Certificate.

Thanks to its extensive network of local branches, which are always associated with the ParkerStore service and ParkerStore sales hydraulics and tires, Chvalis is able to provide rolling stock operators 24-hour warranty and post-warranty service. The ParkerStore retail locations are fully equipped for the production of hydraulic hoses and are certified by the "ParkerStore Hose Certification Workshop." 

Until 2013, Chvalis supplied hydraulic systems only for auxiliary drives, such as compressor drives for compressed air production; the drive for the combustion engine cooling fans and the electric alternator drive for the production of electric motors. In 2013, the company received a call for a comprehensive design and solution for the supply of a complete hydraulic traction drive, including auxiliary drives for 35 units of MUV series 74.02 001-035 series, for CZ LOKO, the manufacturer and supplier of Czech Railways - SŽDC. 

Chvalis has developed a technical solution for its own drive - an unconventional way of using its own innovative, open-circuit hydraulic system instead of competing with a preferred closed circuit. The system, while technically more demanding, precisely and comfortably addresses all the requirements of all traction control conditions controlled by the parent electronic control system of the vehicle. In addition, the circuit allows for hydraulic braking, which was used for the cruise control system. This makes the work of the drivers more efficient and saves the cost of the vehicle operators, reducing the wear of the brake discs of the standard pneumatic braking system of the vehicle. The standard brake is used most of the operating time, using this circuit for braking, until the vehicle stops. 

Hydraulic circuits are built using the Parker product portfolio, including Ermeto E02 pipe systems and hose systems from certified hoses for rolling stock. These hydraulic circuits, mainly PV-plus piston control pumps in conjunction with the  F11, F12, F1, F2, and F14 hydraulic motors of the V14 series, deliver a minimum fault, provide high reliability and long service life.

Thanks to previous experience with the 35-piece MUV74.02 series, Chvalis was asked by CZ LOKO's customer for the design and delivery of a complete hydraulic traction drive and auxiliary drives for a new series of 50 MUV 75.00 Universal Motor Vehicles. This new unit had the requirement to maintain the same hydraulic traction drive that has proven itself in the past series. In addition, the requirement to increase the hydraulic proportional brake power and increase the number of auxiliary hydraulic circuits has been accepted: hydraulic hand, grass mower, hydraulically independent trolley tipping system, and suspension lock. 

After the demanding testing of the first prototype in December 2017, the production of a 50-piece series of cars was launched in January 2018, again using the innovative Chvalis hydraulic system with proven hydraulic components from Parker.

InnoTrans is the leading international trade fair for transport technology and takes places every two years in Berlin, Germany. Sub-divided into the five trade fair segments Railway Technology, Railway Infrastructure, Public Transport, Interiors, and Tunnel Construction, InnoTrans occupies all 41 halls available at Berlin Exhibition Grounds. The InnoTrans Convention, the event’s top-level supporting programme, complements the trade fair.

A unique feature of InnoTrans is it's outdoor and track display area, where everything from tank wagons to high-speed trains is displayed on 3,500 metres of track. Visit Parker at Booth 206, Hall 10 or learn about our innovations to keep you on track on our solutions page. 

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Ray Clapp, owner of Coast Range Construction, Homer, Alaska, was searching for a way to increase efficiency on jobsites. In business for 16 years, Coast Range specializes in setting foundations for lodges and cabins as well as performing house-site development for contractors. Homer has very little flat ground to build on. Terrain ranges from sea level up to 1,400 feet in elevation, and drainage issues are quite common. On many jobsites, it is difficult to maneuver machinery, particularly in tight spaces. Machines often need to be moved several times during a job which can extend the time of a project. Additionally, the challenging terrain is often only accessible by water. Equipment has to be transported by barge. In order to differentiate himself from the competition, Clapp needed a tool that could easily work in tight spaces so that the work could be done cleaner and faster.

Clapp ultimately purchased the PowerTilt tilting coupler and added it to his Hitachi ZX200LC. With PowerTilt’s 180 degree side-to-side tilt and versatility, he can operate his Hitachi with surgical precision cutting all the slopes and angles with just one machine and without having to move it several times during the day.

“The PowerTilt is my secret weapon. It has increased the quality and efficiency of our work to give us the edge over the competition.”

Ray Clapp, owner, Coast Range Construction

PowerTilt uses an innovative sliding-spline operating technology to convert linear piston motion into powerful shaft rotation. Each actuator is composed of a housing and two moving parts – the central shaft and piston. As hydraulic pressure is applied, the piston is displaced axially, while the helical gearing on the piston OD and housing’s ring gear cause the simultaneous rotation of the piston. PowerTilt’s end caps, seals and bearings all work in tandem to keep debris and other contaminants out of the inner workings of the actuator, prolonging product life and reducing required maintenance.

The PowerTilt can be used with a variety of attachments. Coast Range mainly uses it for grading projects but some projects have seen the need to attach standard or narrow buckets.

• Drainage site work: Whether Coast Range is creating a drainage system for a commercial or residential site or digging out dirt for a septic system the PowerTilt can make the finished look impressive.
• Site development: They can easily work on cutting through slopes and swales without moving the machine several times. With the 180 degrees rotation on the PowerTilt they are able to slope and grade the site with one machine.
• Dock building: The PowerTilt is used as a pile driver to push the pilings of the dock down into the ground under the water. Ray will tilt the PowerTilt at an angle to be able to drive the piling into the ground better.
• Rock: The River Teeth attachment with the PowerTilt helps Coast Range rip through rocks in the soil. They can position the PowerTilt at angle to rip rocks out on a slope or ditch.

Coast Range used to require three machines for any given project: the Hitachi excavator, a track loader and a small dozer. By adding the PowerTilt to his excavator, projects were completed one to two days faster. The small dozer was only being used an average of 90 hours a year where most machines average about 2,000 hours a year. Clapp estimates a 30 percent increase in productivity with the use of this tool. He also decided to eliminate the small dozer, and now saves one third of the time to complete the same work he used to do with the small dozer. Reduction in equipment decreases transportation costs too.

Purchasing the PowerTilt has given Ray an advantage over the competitors in the area by increasing productivity and creating a clean and more precise finished look on the jobsite. In using this tool for the past 10 years he has had no maintenance issues or downtime.

The PowerTilt is reliable. The PowerTilt has outlasted Clapp’s machinery. Regular scheduled maintenance and greasing have been key but ten years later, Coast Range’s current PowerTilt has up to 8,000 hours on it and is still going strong with no maintenance issues. Clapp has a lot of confidence that the PowerTilt will always finish the job in any type of weather, terrain or environment in Alaska.

PowerTilt is available for equipment up to 75,000 lbs in eight sizes with standard rotation of up to 180 degrees. Each model is designed for a specific class of machinery and individually customized to fit the carrier.

More product information can be found on PowerTilt here. 

This article was contributed by Jessica Howisey, marketing communications manager, Helac Business Unit, Cylinder Division.

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Not so long ago, only the largest OEMs could afford to develop complex proprietary control systems. But the recent introduction of versatile digital ecosystems connecting electronic control hardware and software to the Cloud is expected to be a game changer for mobile hydraulic machinery and equipment manufacturers.

By empowering design engineers with real-time access to the most sophisticated data collection and monitoring capabilities, such systems are enabling OEMs to customize electro-hydraulic control parameters to meet highly specific application requirements.

This leveling of the playing field is catalyzing a new era of mobile machine and equipment design innovation, as OEMs across industries, tiers and geographies develop customized solutions that digitally integrate their customers’ hydraulic and machine controls with the Internet of Things (IoT). This article will explore some of the major operational and safety advantages of integrated electro-hydraulic motion control platforms connecting mobile machinery and equipment to the IoT.

Whether customers are managing a fleet of transport trucks, utility vehicles, refuse collection trucks, and material handlers, or complex construction, agricultural and mining machinery, the ability to conduct real-time monitoring of vehicle functions and operator performance enables:

• Increased productivity through predictable maintenance and improved uptime

• Improved customer satisfaction and loyalty through proactive data-driven service engagement

• Improved equipment operator safety, including the ability to field-validate training certifications

• Optimized efficiency in energy and fuel usage

• The ability to continually track performance variables such as vehicle locations, engine speeds, torque, pressure levels, and aspects of operator behavior

• The ability to selectively share data across the distribution and supply channels by assigning multi-tiered user types and permissions

• Comprehensive reporting for analysis and improvement

To learn more download the full white paper Today's Digital Ecosystems Take Mobile Hydraulic Systems to a New Level. 

Article contributed by Clint Quanstrom, IoT general manager and Hector Rodriguez, IoT product manager, Motion Systems Group, Parker Hannifin Corporation.

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In today’s industrial manufacturing environment, hydraulic cylinders are complex devices that incorporate a wide range of components available in a multitude of sizes, configurations and materials. When it comes to complex hydraulic systems, cylinder specification can be a balancing act for OEM design engineers — as each design factor influences one or more of the many other design details to be considered for the application.

Even though hydraulic system design guidelines like NFPA and ISO exist, many industries have developed their own. Certain cylinder manufacturers offer options that present a wide scope of performance capabilities for standard components, minimizing the need for customization. However, exceptions to this remain. Working with an experienced engineering manufacturer can help to navigate and expedite the design process.  

In this blog, we’ll look at some of the many factors that should be considered when specifying hydraulic cylinders and how to simplify the process. 

To read all of the factors to consider when specifying hydraulic cylinders, download the white paper “The Art of Cylinder Specification”. 

Medium-duty hydraulic systems with pressure capabilities of 1000 PSI are used in the majority of industrial applications. Some applications, such as hydraulic presses and automotive manufacturing require heavy-duty systems. Standard heavy-duty hydraulic cylinders can accommodate pressures as high as 3000 PSI. Load capabilities are relative to the full piston area (in square inches) when exposed to fluid pressure multiplied by the gauge pressure in PSI. 

Pressure rating can be a concern with custom stroke distances above 10 feet (3.05m). To handle the load, rod diameter must be determined. A pressure rating on load in thrust (push mode) may need to be specified. Rod sag from horizontal applications may result in premature rod bearing wear. To optimize hydraulic system performance, a best practice is comparing the positive effects to any potential negatives. 

The definition of “excessive speed” can vary from one design engineer to another. As a good rule of thumb, standard hydraulic cylinder seals can easily handle speeds up to 3.28 feet (1 meter) per second. The tolerance threshold for standard cushions is roughly two thirds (2/3) of that speed. For higher speed applications, a standard low-friction seal is the better choice. But, what you gain in one aspect of performance, you lose in another. The greater the fluid velocity, the higher the fluid temperature, so when opting for speed increasing customizations, it is essential to consider the impact of higher temperatures on the entire hydraulic system. In some hydraulic systems, over-sized ports may eliminate escalated temperature concerns.
 

Hydraulic cylinder systems using standard components can be designed to meet application temperatures as hot as 500°F (260°C) and as cold as -65°F (-54°C). But temperatures affect both the “hard” and “soft” design components of cylinders. Applications requiring temperature extremes at either or both ends of the temperature spectrum require extensive knowledge of the interdependence of individual components to achieve the best balance of short- and long-term performance expectations. For example, applications near the north or south poles will see a contraction of the seals and metal parts due to the extreme temperatures.

There are basically three categories of mounting styles. Fixed and pivot styles can absorb forces on the cylinder’s centerline and typically include medium-duty and heavy-duty mounts to accommodate thrust or tension. A third category of fixed styles allows the entire cylinder to be supported by the mounting surface below the cylinder centerline, rather than absorbing forces solely along the centerline. Several standardized mounts are available within these categories. OEM design engineers can use these various mount offerings for a wide range of application requirements. NFPA Tie rod cylinders, which are used in the majority of industrial systems, can usually be mounted using a variety of standard mating configurations from trunnion-style heads and caps to extended tie rod cap and/or head end styles, flange style heads, side-lug and side-tapped styles, a range of spherical bearing configurations, and cap fixed clevis designs. Most mounting options are available for both single acting and double rod cylinders.

The goal of every mounting design is to allow the mount to absorb force, stabilize the system and optimize performance. Cap end mounts are recommended for rods loaded primarily in compression (push). A head end mount is recommended for rods loaded in tension (pull). The amount of tension or compression determines the piston rod diameter. The amount of pull or push determines the bore diameter. Other relevant factors to consider when selecting a mounting style include:

• Load

• Speed

• Cylinder motion (straight/fixed or pivot)

Every mounting type comes with benefits and limitations. For example, trunnions for pivot-mounted cylinders are incompatible with self-aligning bearings where the small bearing area is positioned at a distance from the trunnions and cylinder heads. Improper use of this type of configuration introduces bending forces that can over-stress the trunnion pins. Many performance expectations that appear to require atypical mounts can be accommodated by existing styles, sometimes with only slight modifications — facilitating replacement and reducing costs. 

Bore size is related to operating pressure. The amount of push or pull force required is what determines the bore size needed. Earlier generations of steel and aluminum mill equipment often required the use of non-standard bore and rod sizes. Today, virtually every industrial requirement can be met with NFPA standard and/or ISO-compliant components.

OEM design engineers probably request customization of piston rod sizes more frequently than any other hydraulic cylinder component. What is not always considered is the simple fact that push or pull is never independent of stroke length. Just as a pushed rope holds a straight line only in relation to its length (the longer the rope, the more the rope curls), piston rods under compression or tension tend to diffuse force in non-linear directions. Specifying costly materials such as stainless steel or alloy steels for the rods themselves is unnecessary. In most extreme applications, chrome plating provides a high level of corrosion-resistance required to optimize system longevity. 

In conclusion, hydraulic cylinder specification can be a time-consuming and complicated process. Partnering with an engineering manufacturer experienced in hydraulic system design, such as Parker Cylinder Division, early in the design process, an OEM design team can save time and money and ensure reliable system operation and long service life.
 

Download the white paper “The Art of Cylinder Specification” to read all of the factors to consider when specifying hydraulic cylinders.

​This blog was contributed by Jim Hauser, senior engineer, and Rade Knezevic, division sales manager, Parker Cylinder Division.

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Check valves are typically thought of as a very simple component of a hydraulic process. They permit the flow of fluid in one direction and prevent flow in the opposite direction. Simple, right? However, these devices can be one of the best fail safes your process has against a very costly shutdown. Faulty valves can have enormous consequences if they are not functioning with the utmost precision.

Beyond flow control, check valves may also be used as a directional or pressure control in a system. If the pressure becomes higher on the wrong side of a valve, it will close and block flow in the opposite direction. This means the check valve will stop pressure spikes back to the pump. Depending on your process, fluid can flow from a pump through the system at very high speeds. If something in the process suddenly causes the fluid flow to be restricted, the pressure in the line can quickly increase by two to three times, causing damage to the system. The check valve should then close and block the pressure spikes back to the pump.

A check valve can end up costing companies thousands of dollars in replacement pumps and exponentially more in machine downtime. Downtime is one of the largest sources of lost production time in industrial processes and unplanned downtime can be one of the greatest expenses. When unplanned downtime happens, the cost of overhead is still there being consumed, and no value is being produced. These are the most obvious costs of unplanned downtime, but what about the underlying costs as well? Downtime also throws inventory levels off resulting in less than optimal on hand inventory which can lead to increased operational costs. Also, when employees have to focus on fixing a downtime issue this takes away from time they could be using to innovate and create growth opportunities for the company.

One of the highest concerns of a check valve failure is the safety. If a check valve fails, the potential for leakage or even a blow-out is a possibility. A blow-out occurs when the shaft-disk in the valve experiences a separation. This type of failure has occurred even when valves are being operated within their temperature and pressure limits, further justifying the utilization of a high quality product. While a catastrophic blow-out from a faulty valve may be rare, even the smallest of leaks can create safety hazards that can be dangerous for the operators. Ensuring that your check valves are well maintained, and of high quality can help mitigate these risks.

Parker C-Series Check Valves have fully guided poppets. Their superior design eliminates wobble and erratic travel that can commonly occur with less durable ball check constructed check valves. The soft seal poppet on the check valves are standard for sizes up to 1/2” NPT, #10 SAE. They can withstand pressures up to 5000 PSI and flow rates up to 150 GPM. Customers around the world recognize the Parker brand as the benchmark for high performance and best in industry quality. In a product as small as a check valve, performance and quality can lead to big savings in the industrial process.

Parker C-Series Check Valves and N-Series Needle Valves are now available for purchase on Parker.com. Simply add products to your cart for shipment within two days for in-stock items.

Article contributed by Matthew Davis, to be named, product sales manager, Hydraulic Valve Division, Parker Hannifin Corporation.

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Washing a car effectively takes more than soap and water; it takes proper equipment. At the heart of the operation is the motor. Motors actuate brushes, cars, water-hoses and more within a car washing system. Because these motors must operate for long hours under harsh conditions, motor selection presents a unique engineering challenge. For example, electric motors last longer, but can be more expensive. Conversely, hydraulic motors are more cost efficient, but reputed to suffer periodic oil leaks.

While electric motors appeal to consumers because of their longer life, applications in water-rich environments can lead to issues. Water and electricity do not mix. Leaks, rust and corrosion are prevalent in a car-wash application and can lead to premature failure.

In addition to problems with water, an electric motor’s long life comes with a cost.  Simply put, electric drive motors are more expensive. Typically, electric gear motors cost four to five times as much as a hydraulic motor with comparable performance. If repairs are required, electric replacement parts cost more as well.  However, in an application that requires long life, the costs of an electric motor may be justified.

A hydraulic motor is more cost effective, but has the reputation of creating a mess. While hydraulic lines can break and lead to oily spills, hydraulic motors should operate indefinitely, if proper system maintenance is followed:

• Regular inspection and replacement of worn hydraulic hoses
• Use of stainless steel tubing
• Standard maintenance of hydraulic power unit tank to the float level

When water and metal is involved, corrosion is a concern.  By design, hydraulic motors can withstand corrosion in a way that electric motors cannot. Unpainted and sealed hydraulic motors form a rust coating that allows the motor to adapt to a wet environment, without compromising motor performance.

Parker Low-Speed/High Torque (LSHT) motors are used in conveyor systems, wheel polishers and/or brushes. They offer a two-pressure zone, high pressure shaft seal that does not require a case drain line back to the reservoir. This design reduces cost, while retaining possible leak points on fitting and hose lines. The internal flow passage of the motors allows oil to reach all internal components, keeping fresh oil at the internal bearing and ensuring seal shaft lubrication. Fresh oil for components means longer life. 

Robust bearings withstand higher side loads for applications that may require chain or sprocket shaft connections such as the car conveyor. The rugged construction of the TK series motor can transmit over 23,000 lb-in of torque in a compact, 6 x 10 inch package.

Discover more in this interactive video about Parker’s motors used in car wash application motors. 

Click image to launch page:

Article contributed by Hersh Chaturvedi, business development manager and  Kenney Ricker, product manager, Pump and Motor Division, Parker Hannifin Corporation.

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Simplifying user interface and machine system design requires expertise and products. Often machines require a simple, cost effective weight measurement system to improve loading or processing of materials.

The ability to measure the weight of a container or packager in applications such as material handling or fruit harvesting is important to both optimize and measure productivity. If a wheel loader operator can measure the weight of each load in real time and calculate a cumulative weight, it helps measure productivity. Determining the weight of a material transferred helps minimize the number of truck loads required. In harvesting, the real-time measurement of the load of each container can increase productivity by making sure each load is filled, without being overweight. As a matter of fact, highlighting errors and overweight conditions help increase productivity and machine up-time. Icon images and text messages dynamically shown on the screen are extremely helpful for improved operator feedback as well as to clarify error codes and messages.

The PHD line of touch screen displays provides this functionality when coupled with pressure transducers. PHD based load weight measuring systems provide a unique solution to customers who are seeking a cost effective, basic load weight measuring system. The PHD28 offers more capabilities than standard number displays through dynamic screens that show the operator error and system fault messages, over weight conditions, color coded icons, messages and multi-lingual capabilities. These features help improve operator productivity as well as increased up time through faster, clearer diagnostic messages. In addition, the onboard CAN communication allows the PHD to interface with other devices to help automate loading and weighing processes for even better machine productivity. PHD28 is available as a standalone or as part of an integrated solution. 

The PHD28 has a dynamic screen that changes based on the weight and system condition as well as including an operator interface.  In addition, it has built in processing power to perform the basic calculations to measure the weight, check the pressure sensor inputs for faults, rescale values in metric or imperial or even change the font size and icons on the screen. System productivity can be improved since the screen can change dynamically, based on weight, system faults or user errors to highlight conditions that could slow down or stop the weighing process. With its compact, 2.8-inch size, it suits many consoles and dashboards without compromising valuable space.

In this example, two pressure sensors read the pressure on both the rod and piston side of a hydraulic cylinder while checking the inputs values and scaling the readings. The PHD28 has the processing power to calculate the corresponding force of the cylinder based on the cylinder dimensions while the weight of the container can be calculated as well.  In addition, it can be used as the operator interface to perform the tare calculations, store the value and then compute the weight of the payload. The PHD28 offers the functionality of the weight display, operator input device and the system information center in one unit to help reduce costs and save dashboard real estate.

Learn more about our electronic solutions or contact an engineer (link to contact us form on web site).

Article contributed by John P. Thomas, regional application engineer, Electronic Controls Division, Parker Hannifin Corporation.

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Check valves are commonly applied to a variety of load holding applications that are found, for example, in mobile equipment in mining, construction, or forestry. Typical thread in cartridge style check valves are large and mount to the surface of a manifold block. This surface mounting adds to the complexity and cost because of the additional machining or drilling of internal passages required to integrate the valve into the circuit. The compact design of Parker’s new thread-in cartridge valve is an ideal solution because it allows for an internal mount.

The CVH021 can be compact in nature because of its application; used in circuits to isolate pressure signals to flow compensators and load sense lines for pumps. Load sensing is a common methodology used for pump control on many multifunctioning hydraulic circuits that use a variable displacement pump. In load sensing circuits with two or more functions, it is important to use check valves to isolate the signal from each function. This ensures that the pump control is receiving the highest pressure signal in the circuit while multiple functions are being used at the same time. (The pump control receiving the highest pressure means the pump output is increased to meet the demand of the highest demand function).

When used as a pressure sensing isolation check valve, the need for zero leakage and flow rates over 4 LPM (1 GPM) are not required. Standard check valves are available in a C8-2 or C10-2 cavity configuration but these are large and costly, given the number of check valves needed. The cavity can also restrict the placement within a manifold. The schematic above shows an example circuit where isolation checks are used.

As with cast iron sectional valves, a common practice to reduce cost and save space was to drill the check valve seat into the manifold then drop in a ball, spring and port plug. While simple in design and function, these types of check valves are not durable, as neither aluminum or cast iron manifold material hold up to the cycling with flow and pressure impacting the ball onto the seat. Further complications arise for service since it can be difficult to change out in the field with loose springs and balls. If the seat is damaged, there is no service possible and the entire manifold would then need to be replaced.

When used as an isolation check valve, the CVH021 provides a good solution. It incorporates the seat and ball in a single cartridge that fits an SAE 2-style port that can be machined in the manifold to be part of the port connections between valves, without the need to be a surface mounted cavity valve. The heat treated seat and ball bearing provide a durable, high cycle design that allows for simple service if needed.

Parker Isolation Check Valves are available from the Hydraulic Cartridge Systems Division. Consult your HCS catalog or www.parker.com/hcs for more information. You can also contact a Product Manager or Technical Support Specialist for help at 847-955-5000 or HCSTechnical@parker.com.

Article contributed by Bill Guse, senior principal engineer, Hydraulic Cartridge Systems Division, Parker Hannifin Corporation.

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Industrial OEMs and end users rely on traditional tie-rod cylinders to deliver power to industrial presses, mills, foundries, power generation, oil and gas exploration and other extreme, heavy duty applications.

As the workhorse of the industrial cylinder market, tie-rod cylinders perform reliably and offer tremendous flexibility including several mounting options, cushions, position feedback, etc. However, tie-rod cylinders do have some limitations, particularly in longer strokes. Serviceability can be a concern, due to the added complexities of assembling and torquing long tie rods. And for some design-sensitive applications, the visible tie-rod profile can be aesthetically disruptive.

For operations where such concerns are an issue, the introduction of a new class of heavy-duty, non-tie-rod cylinders will be welcome news.

For applications with longer strokes, our 2HB and 3HB non-tie rod cylinders offer reduced complexity and weight versus comparable tie-rod cylinders. Parker’s 2HB and 3HB Series of cylinders are available in 1½" to 14" bores sizes and are dimensionally interchangeable with their tie-rod counterparts, since they adhere to the same industry standard - ANSI/(NFPA) T3.6.7R3 – 2009.

Tie-rods are eliminated through an innovative design which utilizes flanges threaded onto both ends of the cylinder body. The head and cap are bolted to the threaded body flanges with Socket Head Cap Screws (SHCSs) with a small gap between. That gap allows for the head & cap to be preloaded against the end of the cylinder body when the SHCSs are torqued.

The resulting configuration presents a cleaner, more aesthetically pleasing design. Perhaps most importantly, 2HB and 3HB cylinders enable industrial users to achieve current levels of performance while eliminating tie-rod-related fatigue and maintenance concerns. These non-tie-rod cylinders meet NFPA fatigue tests for reliable performance using standard, field-proven components. They are built to a design safety factor of 4:1 on burst.

To learn more about the benefits of using non-tie rod cylinders for your long stroke industrial applications, download our Long-Stroke Industrial Cylinder Performance white paper.

Improving hydraulic cylinder performance in long-stroke applications is a challenge for industrial OEMs and operators alike. For their heavy-duty industrial applications, replacing traditional tie-rod hydraulic cylinders with non-tie cylinders can extend service life, reduce downtime, increase throughput and ultimately increase the profitability of applications requiring stroke lengths over five feet. For OEMs incorporating cylinders into heavy-duty industrial equipment and machines or into apparatus where design aesthetics are important, non-tie-rod cylinders offer several differentiating benefits for competitive advantage.

Tie-rod cylinders will remain the workhorse of the industrial world, but for those applications demanding long-stroke performance, there is now a viable alternative capable of meeting the high-performance expectations of extreme-duty environments.

To learn more about using non-tie rod cylinders for your long stroke industrial applications, including a university architectural application case study, download our Long-Stroke Industrial Cylinder Performance white paper. 

Article contributed by Bruce Kohlmeyer, engineer manager, Parker Cylinder Division.

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A massive engineering and design collaboration have brought the vision of world-renowned Spanish architect Santiago Calatrava Valls to life in Lakeland, Florida. The new Innovation, Science and Technology (IST) Building at Florida Polytechnic University will serve as the central building for the campus of Florida’s newest state institution, dedicated to a curriculum of science, technology, engineering, and math. It houses classrooms, auditoriums, administrative offices, common areas and a number of cutting-edge laboratories; including a Supercomputer and Student Data Center, a Visualization and Technology Collaboration Lab, and a Rapid Application Development Makerspace Lab with 3D printing capabilities. The $60 million, two-story building also includes a system of 94 louvered arms that raise and lower to track the sun above a glass roof.

Each louver is manipulated by a Parker Series 2HB Mill-Type hydraulic cylinder. The custom application required five different sized cylinders, with larger cylinders for the longer louvers at the center of the roof and smaller cylinders for the shorter louvers at the ends.

“We are pleased to have supported this highly customized cylinder application with full integration capabilities and precise engineering,”
Tad Brown, cylinder application engineer, Parker Hannifin Cylinder Division

Specified by Parker distributor Atlantic Hydraulic Systems, based in Shirley, N.Y., each cylinder was assembled with integrated cartridge valves on a manifold, which was bolted to the cap and plumbed to the head end of the cylinder. Further, a spherical rod eye was installed at the rod end, and the entire cylinder was painted to match the remainder of the structure. This full integration, along with special pressure decay testing, was all accomplished within Parker’s Cylinder Division in Goodland, Indiana.

The cylinders act independently from one another and can manipulate the louvers to provide shade and artistic motion. The louvers were designed to eventually accommodate a system of photovoltaic tape to generate power for the campus. Each louver arm is engineered with the capability of a maximum upright position of 65 degrees above the horizontal plane and a maximum lowered position of 48 degrees below the horizontal plane. Traveling the full 113-degree distance takes about 10 minutes.

Construction of the 162,000 square foot IST building took 28 months and was completed by Skanska USA. Headquartered in New York, Skanska USA is one of the largest construction and development companies in the country with expertise in construction, civil infrastructure, public-private partnerships and commercial development initiatives in select U.S. markets. Florida Polytechnic welcomed students for the inaugural day of classes on August 25, 2014. The University offers six undergraduate degree programs with 19 unique areas of concentration and two masters degree programs in the College of Engineering and the College of Innovation and Technology.

The 2HB cylinder design in long-stroke industrial applications is an engineering breakthrough that is expected to extend service life, reduce downtime, increase throughput and ultimately increase the profitability of industries requiring stroke lengths over five feet. For OEMs incorporating cylinders into heavy-duty industrial equipment and machines or into apparatus where design aesthetics are important, the 2HB Series of non-tie-rod cylinders offer several differentiating benefits for competitive advantage.

Learn more about the benefits of non-tie-rod hydraulic cylinders and how they can improve performance in your heavy-duty, long-stroke industrial applications - download our Long-Stroke Industrial Cylinder Performance white paper. 

For more information on the award-winning IST building and the new Florida Polytechnic University, visit their website.

Article contributed by Bruce Kohlmeyer, engineer manager, Parker Cylinder Division.

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Hoover Dam -- one of the most impressive engineering feats of the 20th century – generates hydroelectricity for millions of homes and businesses across the Southwest, and it’s a constant challenge to keep the vital power source running smoothly. Recently, a team of innovative engineering experts wrapped up a massive multi-year retrofitting and refurbishing project to make the dam safer and more operationally efficient.

The challenge was to overhaul and upgrade a series of 50-foot-tall pressure-relief valves on turbines in the dam’s powerhouse and to convert them to a hydraulic control system. The contract for the project was awarded to Precision Machine & Supply, Inc., (a division of Andritz Hydro), which had been working with Hoover Dam since the 1990s.

“Because of the sheer complexity and logistics involved, this has been the most challenging thing I've ever done. It was complicated to get the old equipment out and put the new equipment in, especially with all the restrictions operating in a concrete structure at the bottom of Hoover Dam.”
Dan Wenstrom, president, Precision Machine & Supply, Inc.

Subcontractors for the complex assignment included Parker Hannifin (led by Greg Paddock, hydraulic territory manager; Regional Manager Steve Camp; and Jeff Sage, product manager for Parker’s Accumulator and Cooler Division) and Controlled Motion Solutions, Inc., (Comoso). The Comoso team was led by Joe Oloffo, Southwest regional manager / systems integrator; Director of Engineering Matt Schoenbachler; and Jeff Geyer, fluid systems manager.

Parker was tasked with designing and manufacturing a series of compressed-gas accumulators, and Comoso was responsible for providing engineering and sourcing the hydraulic components.

Hoover Dam is often called one of the modern wonders of the world. Standing over 700 feet tall and containing more than 3,250,000 cubic yards of concrete, the magnificent structure spans the Colorado River between Nevada and Arizona, forming the 247-square mile Lake Mead reservoir behind it.

The dam generates more than 4 billion kilowatt-hours of electricity each year by taking diverted river water from the lake, under extremely high pressure, and channeling it into giant turbines at its base. The water to drive the turbines is fed by gravity through a series of large pipes called penstocks, which narrow (from 30 feet to 13 feet) as they descend to increase the pressure on the water being forced through. When the incoming water reaches this point, its pressure is 250 psi.

At the bottom of the penstocks, the water then enters the turbine through large steel wicket gates, each over six feet tall and weighing 1,500 pounds. The gates work like Venetian blinds, opening and closing to control the volume of water going into the turbine. As water rushes through the wicket gates, it passes over blades that spin the turbine and drive a rotor inside a generator, which then creates a magnetic field to produce electricity.

Hoover Dam has 17 turbines, each weighing about 700 tons, with generator shafts rotating at 180 rpm. While a turbine is spinning, energy is constantly being created and fed through power lines. However, if there is a sudden break or fault in the line – also called a load rejection – the turbine needs to stop as quickly as possible.

When a rejection takes down a primary line – which can be caused by a lightning strike or actual physical damage to a transmission wire -- there’s no place for that newly generated electricity to go. If that happens, the spinning turbine tends to overspeed, which can cause serious damage to the mechanism. Therefore, the water driving it has to be immediately shut off at the gates and simultaneously diverted around the turbine. However, that necessity comes with problems of its own.

First, if the high-pressure water flow is stopped too abruptly, it results in a powerful “water hammer” effect when the backed-up pressure suddenly and violently slams into an obstruction. (Imagine trying to bring a fast-moving train to an immediate stop.) The water delivery system at Hoover Dam contains kinetic energy to reduce the life of the penstocks.

To avert the dangers of those sudden load rejections, the original designers of Hoover Dam installed large pressure-relief valves (PRVs) which could quickly reroute incoming water to bypass the turbines, thereby taking the generators offline. The first PRVs utilized water head pressure to drive large pistons to close tulip valves.

In recent years, though, questions arose about the original PRVs’ functional consistency and ability to protect the aging water lines. Installation of the turbines at the dam began in 1936, so the equipment and infrastructure inside the power plant were naturally affected by time and use.

“The turbines and all their plumbing are vintage – 80 years old in some cases – with a lot of wear and tear on them. So the Hoover people were very concerned about pressure spikes and the resulting negative impact they could have on the equipment.”

Greg Paddock, territory manager, Parker Hydraulics 

“Over the years, those pressure-relief valves became corroded, agreed Wenstrom. "Also, the original valves were mechanically actuated and water-operated, because that's all the technology they had in the 1930s.”

Aware of the critical need to optimize the reliable performance of the older pressure-relief valves, the operations team at Hoover Dam launched a long-term project to upgrade them. The main objective was to make the PRVs more responsive and functionally efficient when a power line break would necessitate a generator shutdown.

The initial plan called for overhauling the existing valves by taking them apart and restoring worn components to like-new condition. The scope of the challenge – plus the restriction of not being able to shut down multiple turbines at the same time – meant the work would inevitably require many years to complete. Hoover’s plant personnel and Precision Machine began the first remedial work on the valves in 1998 and 1999.

While that work was underway, Wenstrom came up with a unique design concept to standardize operation of the PRVs and make them digitally controlled. The dam’s original generating equipment was built by various manufacturers and installed over a long span of years, so it was far from consistent. There are five separate turbine designs in operation at Hoover Dam. Even units built by the same manufacturer several years apart had differences.

“We showed Hoover a design that would make the units fully compatible with their existing electronic control system that operated and controlled the generators. We proposed converting all PRVs to be operated in the same way and all controlled by hydraulic cylinders.”

Dan Wenstrom, president, Precision Machine & Supply, Inc.

The decision was made to go with hydraulic-driven pressure-relief valves which could provide very precise control and extremely fast response. The system would also reduce the number of false pressure relief valve operations that often occurred with the old mechanically operated PRVs. Wenstrom brought in Comoso to engineer and supply the hydraulic power unit and manifold that mounted to the hydraulic cylinder.

The hydraulic controls also required accumulators for energy back-up. Parker's Accumulator and Cooler Division -- a world leader in the development of customized accumulator applications -- was given the assignment to design the best units for Hoover Dam’s unprecedented requirements. Working closely with Comoso and Precision, Parker was able to implement an ideal, cost-effective solution. An accumulator enables a hydraulic system to respond quickly to a temporary demand, using a less powerful pump.

“Think of the accumulators as very large batteries with high levels of energy to operate the PRVs. The accumulator stores hydraulic energy until it’s needed for immediate use.”

Jeff Sage, product manager, Accumulator and Cooler Division, Parker Hannifin Corporation

Supplemental power from the accumulators is necessary because of how Hoover’s hydroelectric equipment is configured. Ironically, available electricity is very limited inside the huge power-generating facility.

“Where the PRVs are located in the dam, there isn’t much access to electrical power, said Camp. "The dam puts out 185,000 horsepower per turbine, but we only had the equivalent of ten horsepower in the area where we worked.”

The power that's available inside the dam itself comes from two smaller separate generators called “house units” in the powerhouse. The little units simply wouldn't have the energy capacity to operate multiple high-pressure, high-horsepower hydraulic oil pumps to drive the cylinder when a PRV trips.

“The accumulators instantaneously allow 750 to 900 horsepower, so we have the energy we need at the drop of a hat to operate the valves. It opens the bypass very quickly.”

Steve Camp, regional manager, Parker Hannifin Corporation

Each pressure-relief valve at Hoover Dam now utilizes one compressed gas piston accumulator with pressurized oil (180 gallons under 2,750 psi) and two large nitrogen-gas bottles. The accumulators have a 20” bore and an outside diameter of 23 5/8”.  They’re 200" long and have a dry weight of 8,653 lbs.  A total of seventeen accumulators and thirty-four nitrogen gas bottles have been installed.

“It was a huge challenge, and not many manufacturers can build accumulators of this size,” Paddock noted, “but Parker Hannifin was up to the task.”

“As the upgraded PRVs are designed, we now get shaft movement typically within less than a tenth of a second after the signal is received that the generator is going into emergency shutdown,” said Paddock. “As quickly as the (water intake) gates are closing, the PRV has to open to bypass the same amount of water that was otherwise going through the turbine. That’s within ten seconds. And then the most critical aspect of it is once the PRV is fully open, it has to slowly reclose so that no water hammer is created.”

With the installation of each new pressure-release valve, a commissioning team – including representatives from Hoover Dam, Precision Machine, Comoso, and Parker Hannifin – conducts a very detailed testing process.

“To do the commissioning, we bring the generator up to speed and then trip it to simulate an emergency shutdown, Wenstrom explained. "Recording devices with transducers on the turbine side and the PRV side precisely measure the hydraulic pressures, the strokes, and the time it takes the cylinder to respond to the emergency closure signal. Then we measure the amount of time it takes the pressure-relief valve to open and to reclose. The whole idea is that these PRVs have to open very quickly, as soon as the wicket-gate starts to close, to avoid a water hammer.”

In addition to dramatically improving the functionality and reliability of the PRVs, the hydraulically driven system provides a solution to a new problem at Hoover Dam: Quagga mussels. 

An invasive species of Quagga mussels had made its way into the Colorado River and Lake Mead, and by 2009 the mussels actually started plugging up water passageways in the dam’s control valve system. They clog PRVs by clinging to the rods that open and close the valves, and in some cases even prevented them from opening.

“Dan’s design to modernize the PRVs ensured they would operate regardless of any fouling factors such as the Quagga mussels,” said Paddock. “The hydraulic-driven PRV could basically just plow through any obstruction in its path, by brute force. The impetus of the conversion to the hydraulic design wasn't the mussels, but it turned out to be a great secondary benefit.”

The entire process of upgrading the pressure-relief valves and associated equipment has been an extraordinary team effort representing a lot of combined brainpower. Ultimately taking twenty years from start to finish, the scope and uniqueness of the project seem appropriate for such a magnificent historic facility.

“There are many long-term benefits to this whole project, from operational efficiency to safety and more,” said Paddock. “Parker is grateful to have been part of it.”

Article contributed by Parker Hannifin led by Greg Paddock, hydraulic territory manager; Steve Camp, regional manager; and Jeff Sage, product manager, Accumulator and Cooler Division. 

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As the case is across many sectors, electronics systems are the primary drivers of innovation in today‘s agricultural industry. However, those working in this sector may have noticed that any major strides forward in past years have been somewhat hampered by a lack of compatibility between proprietary solutions from different manufacturers.

Fortunately, more recent solutions have been based on ISOBUS, bringing significant benefits to end applications and their users. And now, with the latest technology, combining HMI solutions for both ISOBUS functions and other tractor HMIs are leading to the possibility of just one, convenient, cost-effective and efficient interface for the operator.

A modern ISOBUS system comprises a multitude of components, including the tractor, terminal and implement. Taking this concept a step further, an industry first from Parker’s perspective, the ISOBUS Suite Apps enable the integration of ISOBUS functionalities into the machine HMI (Human Machine Interface), via the app-based Pro Display product family.

Using the apps, ISOBUS functions can be shown on the screen. Since the display offers full flexibility and can show comprehensive information – including machine data, notifications, camera monitors, PDFs and more – no separate ISOBUS display is required.

Farmers have been forced to toil with tractors, implements and machines from various manufacturers on a daily basis. The variety of proprietary solutions meant that many systems did not engage seamlessly or even at all. This disunity saw each implement and tractor requiring an individual terminal to allow data exchange and machine control – a situation that was far from ideal.

Systems based on ISOBUS and utilising tools such as Parker’s ISOBUS Suite apps are driving a shift in the agricultural landscape, making it possible to achieve higher levels of productivity with less operator fatigue.

Using these latest electronic systems, operators can now control and monitor practically every stage of the agricultural process, including tilling the soil, planting seeds, irrigating the land, cultivating crops, protecting them from pests and weeds, harvesting, threshing grain, feeding livestock, and sorting and packaging the products.

In its basic form, the technology facilitating this capability is ISOBUS, an international communications protocol for the agricultural sector that offers plug-and-play functionality and – importantly – only one terminal for a large selection of implements, regardless of the manufacturer. Sounds a lot easier already. Put simply, ISOBUS standardises control settings, reduces downtime and minimises installation and interface problems.

Crucially here, a standardised plug makes it remarkably easy to connect different components, while costs are reduced because it is only necessary to buy a single terminal. Who doesn’t like cost savings? A further benefit of ISOBUS is that it improves operating efficiency and optimises timings, as data can be exchanged between the farm PC and the terminal. With ISOBUS, life on the farm is certainly a whole lot easier; but it could even better.

By utilising Parker’s UX Toolkit– an apps-based software development environment that can be used to develop HMI products for mobile machines and vehicles – and the split-screen functionality, manufacturers can display further machine data and camera monitors right next to the ISOBUS information.

Machine manufacturers can expand the functionality of a device with ease. HMI apps offer an advantage when trying to make mobile machines more efficient, when guaranteeing flexibility in terms of expanding functionalities, and when simplifying processes in the driver’s cab. Less downtime is achieved via diagnostics apps for service code protocols, data capturing and analysis, GPS tracking and geo-fencing, as well as by apps that enable mobile phone hands-free functionality, driver logbooks and operating behaviour tracking.

The UX Toolkit, together with the Pro Display family, also supports functions such as automatic steering, self-levelling suspension and weighing. In addition, the robust displays with capacitive touchscreens are equipped with multiple communications and infotainment interfaces. In short, an apps-based future looks set to enhance the agriculture industry in ways never before imagined.

Learn more about Parker's ISOBUS Suite apps and Pro Display. 

Tommi Forsman, principal engineer, Parker Hannifin, Electronic Controls Division

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Work can be tough, dirty and unforgiving. The last thing you need is for the machine to fail in the midst of a job. Machine failure leads to unscheduled maintenance and an increased amount of time in the field. To prevent this costly downtime, it is essential that fluids are routinely checked and replaced, namely transmission fluid.

Transmission fluid is the lifeblood of a hydraulic system. Without transmission fluid, hydraulic pumps and motors cannot perform the powerful tasks that are required for many different applications. Unfortunately, most hydraulic fluids are merely repackaged mineral oils with contaminants that reduce oil lubricity, high amounts of sulfur that accelerate corrosion and unstable chemistries that lead to phase separation and “gunked-up” gears. Coupled with a 500-hour maximum life, the current market of transmission fluids provides hassle, downtime and uncertainty.

To combat this mediocrity, Parker Hannifin’s Pump Motor Division has developed HT-1000, an engineered oil, molecularly homogenized transmission fluid with the highest starting lubricity, longest life and highest cleanliness standard on the market.

HT-1000 was developed by Parker engineers in partnership with the world’s best formulators over 18 months. The oil combines the best, state-of-the-art “know-how.” Starting with the highest quality, lowest contaminant Group II base oil, HT-1000 is formulated to unmatched molecular homogeneity and packaged to the most uncompromising cleanliness standard. Each transmission developed and built by Parker is tested and shipped with HT-1000 to promote longevity and efficiency.

"The brief going into this project was to create the best hydraulic fluid, ensure the lowest cost, maintain Parker hydraulics and spare no cost or effort in the process. We were clear from the start that we needed to engineer what was missing in the industry, if the laws of science allowed it. If we couldn't leap frog the competition, we weren’t interested. Parker formulated fluids are engineered to deliver best performance and longest maintenance intervals."

Jason Richardson, lead engineer on the HT-1000 project, Parker Hannifin Corporation

HT-1000 is available for purchase online in 1-quart bottles, 1-gallon jugs, 5-gallon buckets and 55-gallon drums. HT-1000 is also available in 325-gallon bulk totes and 5000-gallon tankers by special request.

The Pump and Motor Division is a market leader in gear pump and low speed-high torque gerotor motors that continues to blaze the trail with the development of new technologies while maintaining the high level of service synonymous to Parker. Between its two locations in North Carolina and Tennessee, the division employs decades of industry experience to better serve you and your application.

Article contributed by C.T. Lefler, Marketing product manager, Parker Hannifin Corporation.

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