The world of hydraulic motors is vast with numerous motor types available for various applications. To qualify as a hydraulic motor, a motor must utilize incompressible fluid to convert hydraulic pressure into torque and rotation. In applications that require low speeds (generally less than 1000 rpm) and high torques, an orbital-style, gerotor motor stands above the rest.

An orbital-style motor consists of several roller vanes positioned in pockets around the inside diameter of a stator, that act as a guide for an internal rotor to orbit. The rotor’s rotation is achieved through a pressure differential created by fluid flow. Constantly shifting high- and low-pressure zones are created, resulting in smooth and consistent rotation. Once the fluid has moved through the motor, the fluid can be returned to a holding tank, or directly to the pump itself. The rotor drives an output shaft, which is connected via a “dogbone”-style drive link. This output shaft is connected to whatever is being driven (a wheel, auger, conveyor, etc.), and a high torque can be applied. This direct connection creates a smooth transfer of the required speed and torque for an application.

There are two, smaller groups of low-speed, high-torque orbital motors, two-zone and three-zone. The primary difference between a two-zone and three-zone motor is the inclusion of a case-drain. A three-zone motor uses a case drain as a secondary outlet, where fluid can be returned to a tank (or pump), if the application’s pressure becomes too high. Alleviating this pressure aids cooling and can extend motor seal life. Additionally, the case drain line can drain excess internal oil leakage. This design feature allows three-zone motors to be linked in series for higher-pressure applications, while maintaining the flow levels of a two-zone torqmotor. In the case of a two-zone motor, the absence of a case drain means that extra adapters and hoses are not needed to connect a secondary outlet, making the entire system more cost effective. Two-zone motors can be equipped with high pressure shaft seals to bolster capability, but can not perform in the same, high pressure environments as a three-zone motor.

Parker’s 3Z Series is the latest addition to the Parker Pump & Motor Division’s product portfolio. The 3Z line consists of two, three-zone, orbital-style motors. The orbital-style design reduces friction to a minimum, and increases the efficiency of the overall design, even at high pressures. The 3ZE and 3ZG models can provide up to 24GPM and 40GPM of flow, respectively, making the series ideal for applications across numerous markets. Find out more at www.discover.parker.com/3ZSeries.

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

Visit us in Indianapolis, IN on March 3-6, 2020 at booth #3011 to see the latest in Parker products.

Article contributed by C.T. Lefler, market product manager, Parker Hannifin's Pump & Motor Division.

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A project involving a Parker EHPS (Electro Hydraulic Pump System) has underlined the significant advantages of adopting the latest electrification technologies as opposed to traditional industrial combustion engine (ICE)-driven systems for mobile heavy lifting applications. The project, conducted in partnership with a leading global OEM, showed how real-world challenges faced by all design engineers – reducing costs, increasing operational efficiency and protecting the environment – can be overcome.

The key point of note here is that developing the EHPS met an elementary industry need for decoupled loads and power distribution. A design concept of this type delivers better engine management, as energy storage and recovery functions form a key part of the overall solution. The system can be sized according to specific requirements, providing power on demand, eradicating waste and allowing for capturing returned energy when lowering the load. Contrast this to an ICE, which in heavy lifting applications is sized for peak energy demand and offers no energy storage or recovery capabilities, and the benefits are clear.

The opportunity for OEMs in the mobile machinery arena (and their end users) is significant, especially as an integrated solution such as the Parker EHPS can provide energy cost savings of circa 30% and up to 50% in some applications.

With regard to this specific project, development began back in 2012, with the first prototype emerging two years later. By 2016, Parker’s facility in Warwick had the project ownership and delivery responsibility transferred over. The first orders arrived in December of that year.

Breaking it down in engineering terms, the solution relies on an inverter-driven electro-hydraulic pump sub-system to deliver the lift-lower and telescope functions and enable energy recovery as materials descend under gravity. The IQAN control system and embedded Parker-derived software provide the system function and operational interface, while peripheral manifolds and system components facilitate important services in the wider hydraulics. 

A key point is that by working in partnership with the OEM, Parker could validate in real-life the capabilities and savings possible with EHPS. In short, it could be proven that significant fuel savings would be achieved, while productivity gains with quicker responses in lifting, lowering and driving, were also demonstrated.

Since installation on the vehicle, the OEM reports it is expecting CO2 emissions to be reduced by up to 100 tonnes based on an annual running time of 5000 hours, providing yet another major benefit to the adoption of the system.

Ultimately, a decoupled solution like the EHPS offers a variety of critical benefits to those in the process of developing electric solutions, not least the opportunity to use a smaller ICE, or even eliminate it altogether. And that’s not forgetting gains relating to energy recovery, power on/off demand and the operation not being dependent on the ICE speed, or torque for that matter. 

Learn more about Parker’s EHPS solution.
 

Article contributed by Ciprian Ciuraru, project manager, Mobile Hydraulic Systems Division Europe, Parker Hannifin Corporation.

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Two Solutions to Make Your Construction Machine More Efficient

Transmissions within work truck applications are highly customizable leading to multiple Power Take-Off (PTO) designs aligning with the transmission, chassis and space claim requirements. When it comes to PTO manufacturers, different product series are created to align with the different transmission manufacturers in the market. When installing a PTO on a transmission, a common issue with the installation process is the clearance in the truck chassis with how much room is available for installation. This is where the design and unique configurations of the PTOs are maximized to best match with the transmission applications.  

Installation clearance around the transmission can become problematic for many installers. Not only with the installation of the PTO itself, but attaching pumps may lead to situations of clearance issues that can, therefore, limit the type of pump sizes used. Allison is an example of a manufacturer that makes transmissions with customizable options. Popular transmissions from Allison are the 3000 and 4000 Series with the 3000 Series applying to medium duty applications and the 4000 series applying to heavy-duty applications. For Allison, PTO manufacturers have been creating product series that are designed for their transmission customization options. This is where extended shaft PTOs come into the discussion for the right application.

Extended shafts were designed to accommodate the Allison 3000 and Allison 4000 transmissions which feature a retarder or transmission mounted cooler. Transmission coolers help prevent transmissions from overheating from heavy hauling and towing. Transmission retarders help slow down vehicles when driving situations make it difficult to control the speed such as going downhill. These transmissions may have a transmission mounted cooler attached, a retarder attached or neither. Extended shaft PTOs provide a product series alternative to align with the transmission being used with a transmission mounted cooler and retarder since both impact clearance around the transmission. The design of the extended shaft product series help with these clearance issues.  

Parker Chelsea’s extended shaft product series offerings include the 890 series and the 870-XL Series PTO. The 890 was the first extended shaft PTO. The design keeps the PTO close to the transmission and allows for a large pump to be mounted behind the transmission. The 890 output is just behind the transmission and does not extend beyond the transmission mounted cooler or retarder. The 890 also sometimes allows for a drive shaft to be mounted at a better angle or in the relatively clear area behind the transmission.

When comparing the 870-XL Series and the 890 Series to each other, they both have a torque capacity for each is up to 670 lbs.-ft / 908 Nm. The difference in the design of the two is the 890 Series extends 23 inches from the center of the aperture while the 870-XL Series extends 29 inches. There is approximately 6 to 7 inches of extra clearance with the 870-XL Series. If the 890 has an issue, the 870-XL extends beyond the transmission mounted cooler or retarder to help solve the clearance issue. Another feature with the 870-XL series is the pump flange is rotatable every 7.5 degrees. The pump should be able to be locked to whatever angle it fits best. The 870-XL also allows for larger pump fitment options.

The design of the 870-XL Series has the same main PTO body and internals common to the standard 870 Series. The 870-XL Series is a PowerShift PTO specifically designed for the Allison 3000/4000 Transmissions. The Allison 3000 Transmission is designed for medium-duty vehicles while the Allison 4000 Transmission applies to heavy-duty vehicles. The 870 series already provides a compact housing design that helps eliminate certain clearance issues.

It is important to note what transmission manufacturer is used in your truck application. With a transmission manufacturer like Allison, customization varies greatly with the design of a cooler and retarder. This has led to PTO manufacturers creating product series lines that best match with the unique customization of the Allison transmission and to help improve the end user customizable offering experience as well as the installation process. Other transmission manufacturers may have transmission offerings that have led to PTO manufacturers adapting and design product series to best serve the end-user with a proper PTO for best performance and offerings of customization.

To take a more in-depth look at the 890 and 870-XL PTO series offered by Parker Chelsea, check out our products page which newly features a selection filter of type of transmission manufacturer that will allow for you to easily categorize your search result based on the transmission manufacturer that you are inquiring about.

This article was contributed by Michael Mabrouk, marketing leadership associate, Chelsea Products Division, Parker Hannifin Corporation.  

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Power Take-Offs (PTOs) are designed to pick up engine power through rotation and transfer the power to another piece of equipment. For this to work, a piece of equipment can be mounted to the PTO or it can be connected by a driveshaft. The process begins with the PTO input gears meshing with one of the gears in a vehicle’s transmission starting the rotation. This rotation created from the engine drives the transmission and results in turning the PTO gear and rotating the PTO output shaft. Input gears must mesh properly with the transmission’s PTO drive gear for the PTO to work. But there are a series of gears that must be considered to determine the final output ratio of the PTO.

When analyzing the gears, a measurement term to be familiar with is gear pitch. Gear pitch is the measure of the size of the teeth and is determined by the number of teeth in a given area. To calculate the gear pitch, you would divide the number of teeth by the pitch diameter of the gear. Knowing the gear pitch is important since the PTO gear must have the same pitch as the transmission gear to function properly.

Another measurement term to be familiar with is gear ratio. Modification of the operating speed of the engine to the PTO driven device can be created through the gear ratio. To understand the PTO gear ratio, it measures the revolutions of the small and large gears. Looking at a smaller gear with 12 teeth driving a 24 teeth gear, the small gear makes a revolution with the larger gear only making half a revolution during the 1 small gear revolution. This means that the speed of the larger gear is half of the smaller gear, but the torque and twisting force is twice of the smaller gear.

The gear ratio in this scenario equates to the number of teeth in the driven gear (24) divided by the number of teeth in the driving gear (12). This results in a gear ratio of 2 to 1. The change in torque in this scenario is 1 to 2 resulting from dividing the number of teeth in the driving gear (12) over the driven gear (24).  With the assumption of knowing the engine horsepower and the revolutions per minute (RPM) of the smaller gear, torque can be determined.

T = Horsepower x 5252/Speed (RPM) = Lbs. Ft. Torque

(As you can see from the above photograph, the two gears would lock as so with the red marked teeth)

Product series can have multiple gear ratio options or have just one gear ratio option. To select what ratio makes the most sense, you must know the RPM you want your vehicle’s engine running at for the application and the required operating speed of the driven equipment being used in the application. The ratio of a series of gears creates the speed for the output shaft. Those gears include the input driver gear, the input ratio gear, and the output ratio gear. Their relationship to one another will determine how fast the output of the PTO is spinning in relationship to the engine. The required speed for the driven equipment must be known in order to select the proper PTO ratio. When utilizing pumps, flow rate and displacement are needed to be determined beforehand to make sure the pump input shaft will work with the given speed from the PTO.

When looking into specific product series offered by Parker Chelsea, we want to highlight two different scenarios for series model codes. Starting with our new 210 Series for 2020 Ford Super Duty 10R140 transmissions, this series only has one gear ratio being 46/36 (internal ratio).  When all of the gears in series are considered, the final output ratio is 144% of the engine speed. With this gear ratio, and using a 90% efficiency rating, specific pump options are offered for the 210 Series which include the CGP-P11, PGP-315 and P16 pumps. It is important to remember pump productivity is determined by the pump size in relation to the pump speed.  Therefore, certain pump options may be more suitable than others depending upon the requirements of the application.

The 524 Series Rear Mount PTO is a little different compared to the 210 Series in relation with the gear ratio(s). The 524 Series has gear ratios of 1:1.00, 1:1.33, and 1:1.80. The design of the PTO itself is a two gear mechanically shifted Rear Mount PTO that is attached to rear mount apertures of a transmission. Rear mount apertures are becoming more common in the U.S. with European based transmissions becoming more popularized in the U.S. market. With the three gear ratios, this leads to different torque ratings being available in the market therefore increasing the number of applications that can be used with the 524 series along with optimizing the driven equipment.

Learn more about our 524 Series rear mount and 210 Series ten speed PTO today.

This article was contributed by Michael Mabrouk, marketing leadership associate, Chelsea Products Division, Parker Hannifin Corporation.  

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Mobile off-road machinery complexity has increased significantly over the past five years. Along with that complexity, there are higher expectations of the machine operator.  Operators expect easy to access settings and configurations that provide information about machine productivity. To easily access data, the operators look for cab displays that have high resolution full-color displays. There are several key value drivers for mobile displays that are important to consider when deciding between a traditional gage cluster and indicator lights versus a full color HMI screen.

The more aware the operator is about the status of the machine, the more productive they can be.  A machine could be less productive if the operator cannot easily determine or change the machine’s configurations.  Machine configurations or setting that require a series of button pushes along with indicator lights can be confusing.  If the machine configuration is set incorrectly, the machine may lose productivity and possibly could result in lower fuel economy.  Clear text descriptions and on-screen images allow the operator to choose the correct settings to help optimize the machine’s operation.

Operators appreciate clear text messages and images about the machine’s status.  If an operator is aware of the impending issue through a plain text notification on the screen, they can proactively plan to reduce unplanned downtime. 

The displays allow for multiple, dynamic screens where current and relevant information can be shown on each screen.  For example, a fault condition may automatically bring up a screen with a clear text message about the fault.  From the screen, the operator can scroll to an information screen or a configuration setup screen.

Messages can be displayed in multiple languages for operators to select their language to easily understand machine status.  Because the display offers options for language, there can be  one-part number for the system that can be sold globally.

Many mobile displays support one or more cameras installed in the machine.  Back-up cameras allow the operator to see blind spots when reversing.  Work areas are also viewable by cameras on the displays.  The operator can see the cameras and monitor the work areas for blockages or foreign objects, and most importantly ensure worker safety in the work area.

Display screens can also function as keypads, which allow users to log into a machine before operating. This helps make sure not only that the operator is accessing the correct machine, but also can be used to automatically set the configuration parameters to match the operator skill and training level.

Download Parker's Display Product Selection Guide to learn more.

Article contributed by Kirk Lola, product manager, Electronic Controls Division, Parker Hannifin Corporation.

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The next generation mobile hydraulic pump is designed for mobile and built to perform.  

The  P1M Series Mobile Open Circuit Medium Pressure Axial Piston Pump, increases equipment’s performance and delivers unrivaled benefits, including:

• A smaller footprint
• Less emission and fuel consumption
• Improved machine response time
• Increased efficiency
• Longer pump life
• Reduced noise

The P1M Series is a perfect fit for mobile applications ranging from construction to refuse where system real estate is a premium. Other applications include mining, agriculture, utility, forestry, cranes, material handling and military. 

The P1M Series is compatible with a wide variety of current control options. Optimize your application’s performance by combining your pump with the Electronic Displacement Control (EDC) that improves machine handling and productivity by supplying the exact amount of power in the moment it is needed. 

Other control options include:

• Pressure compensator
• Load sense
• Remote compensator
• Electronic upload 

Check out Parker's Hydraulic Pump & Power Systems' P1M Infographic: 

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Smarter features can aid efficiency and reliability in many applications such as waste collection trucks. This is important to achieve without compromising functional safety or contravention of EC directives.

All refuse collection vehicles (RCVs) must conform to strict quality standards, as well as the requirements of certain current EC directives. In addition, worldwide legislation will doubtless continue to impose lower CO2 emission levels on the industry, driving manufacturers to pursue ever-greener technologies. And then there’s the safety of both operations and all those in and around the refuse truck, which must, of course, remain the number one design priority.

In short, there’s a lot to consider. Until now, the RCV industry’s answer to this challenge comprised of little more than a basic PCB with a processor, providing no flexibility and, frustratingly, no opportunity for modification. In addition, there has emerged a clear market need for remote logging and diagnostics capabilities.

The recently introduced IQAN-MC4xFS controllers have been developed to offer a more cost-effective way of meeting the safety standards necessary for RCVs. Designed for controlling hydraulic valves and certified to IEC 61508 SIL2, the IQAN-MC4xFS incorporates a considerable amount of monitoring functionality to better serve application requirements. For example, extended diagnostics measures have been introduced that include the run-time diagnostics of potentially dangerous faults, along with extensive start-up tests.

Among those already enjoying the benefits of adopting IQAN-MC4xFS controllers is Kaoussis, a leading waste management equipment manufacturer in Greece. The company sought a remote logging and diagnostics system offering flexibility, compliancy and local support.

Drawn to the IQAN-MC4xFS, Kaoussis duly provided an RCV truck to evaluate the Parker system. The use of remote diagnostics in the truck, which is designed to collect both recyclable and non-recyclable waste, was successfully tested and subsequently commissioned for use in Portugal.

The system helped Kaousiss achieve some important application-specific benefits. These included the ability to remotely log and monitor parameters such as tyre pressure, high oil temperatures and hours of operation, as well as registering ‘errors’ such as the triggering of the foot bar or light curtain by operators. In addition, some parameters, such as timers, could be adjusted, again remotely, alleviating the need for time-consuming and costly travel.  

The connection of the truck to a remote location where parameters could be monitored or adjusted in real-time, was achieved using IQANconnect. This is Parker’s remote diagnostic service which allows customers to connect to their machines over the Internet. IQANconnect integrates hardware and software into a single system, offering easy access from the cloud to ultimately help customers reduce downtime and be more productive.

As a final point, the IQAN-MC4 family of controllers all share the same pinout, making it easy to scale the application up or down if required. Each controller is available as either a performance-optimised standard unit, or an IEC 61508 SIL2 Functional Safety (FS) variant. Furthermore, when applying EN ISO 13849-1 for safety functions, the FS variant can be used as a PLd subsystem.

Smart, yet safe, RCVs are finally an affordable reality. Learn more about Parker IQAN-MC4xFS controllers  

Article contributed by Johan Liden, product manager, IQAN Electronics, Parker Hannifin Corporation.

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Modern Digital Ecosystems Take Mobile Hydraulic Systems to a New Level

Configuring a hydraulic pump or motor to your exact machine requirements can be complex, time-consuming and involve multiple points of contact with customer service. Our focused response to this challenge has been to create for our customers and business partners a more efficient on-line experience when configuring product. Our engineers and product managers at  Hydraulic Pump and Power Systems (HPS) created a new online econfiguation tool now available for its Gold Cup Pump and Motor Series.

The new eConfigurator online tool will provide a more enhanced user experience and greater efficiency than the prior version. The new tool enables users to more easily configure a hydraulic pump or motor specific to their exact requirements. In addition, users will also benefit from the tool's capability to only configure products that are consistent with the Parker product offering, providing them with the expertise of Parker at their fingertips.

This post will walk you through the following upgraded eConfigurator functionality including its: 

• ​Improved design and layout​
• Additional detail and specification​
• Enhanced collaboration​
• Streamlined quoting

The eConfigurator's improved design and layout includes the following features: 

• Embedded CAD view: A new embedded 3D visual to review general dimensions prior to downloading a CAD file.
• Dynamic filter navigation: As choices are made in the selection pane, the Configuration Code changes accordingly and highlights designators impacted by the user section.​
• Search by configuration code: Automatically populate all selections of the eConfigurator by entering an existing, complete configuration code into the search field, resulting in a full product summary. 
• Special options specification: If “Special Modifications” are selected, additional drop-down selections will appear.
• Tool tips: Hover over "i" button for quick tips on the selected attribute. 

The eConfigurator's new additional detail and specification capabilities include the following features: 

• Built-in intelligence: Intelligence to check the compatibility of selections, which will prompt an acceptance of changes for any incompatibilities. ​
• Extended summary: Technical data specific to the model configured that now includes an additional 17 specifications direct from the sales catalog.

​The eConfigurator's enhanced collaboration features include: 

• Copy to clipboard: Copy the configuration code/part number to a clipboard for ease of sharing.
• Share via email: Select the share configuration button and enter an email address to share your configuration.
• Save the configuration: By clicking the "save configuration" button, your information will be stored to the web browser for future use. 

The eConfigurator's quoting functionality includes:

• A streamlined quoting process: Electronically send your detailed product configuration for a pricing and delivery quote.

If you would like to learn more or test drive the new Gold Cup eConfigurator, click here.

Article contributed by Dave Ebert, product manager for Parker's Hydraulic Pump and Power Systems (HPS)

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Part 1 of 2: Choosing an Efficient Electric Motor for a Hydraulic Pump

Part 2 of 2: Choosing an Efficient Electric Motor for a Hydraulic Pump

Mining trucks encounter heavy, frequent loads throughout their life cycle and replacing their large tires, which could be in the realm of 13 feet or even larger, can occur as much as 4 to 6 times per year. Historically, these massive, worn-out mining tires have been stockpiled, buried and just abandoned at the mine site. Mining companies face the challenge of what to do with all these old tires. Transporting each tire entirely in-tact is costly and cumbersome due to their scale. Simply leaving the old tires at the mine site, can release toxins into the environment and create a breeding ground for pests, such as mosquitoes.

Eco Green Equipment, a tire recycling equipment manufacturer, identified that the disposable of old mining tires was a worldwide issue and discovered how taxing it was on mining companies and the environment. As a result, they worked to develop the Eco Green Off The Road (OTR) Mining Tire Solution, consisting of three pieces of equipment that provide mining companies with the ability to more easily move and recycle their old truck tires. Now instead of these tires disintegrating and taxing the environment, they are another revenue stream for the mining company.

The first piece of equipment is the Eco Razor 63, which removes the good rubber from the tire’s tread and sidewalls and turns it into high-quality recycled rubber, or premium rubber mulch. Premium rubber mulch, used frequently in high-end landscaping and playgrounds, can be lucrative due to its high demand.

The Eco Extractor 63 is the second piece of equipment. It removes the steel bead from the large mining tires, which can then be sold and recycled into other steel products.

The third and final piece of equipment is the Eco Shear 63, which reduces the giant buffed and debeaded tire into much smaller pieces. The result is a more transportable tire remnant that can be delivered to a rubber recycler or further ground through a tire shredder, such as the Eco Green Giant.

During the development phase for the OTR Mining Tire Solution, Eco Green reached out to their existing partners, including Parker’s Hydraulic Pump and Power Systems (HPS) and a distributor to help in the development of the robust hydraulic systems tailored for the Eco Razor and Eco Extractor.

The result was a hydraulic system substantial enough to support each equipment’s unique requirements, including:

• The Eco Razor’s shock load from the buffing head and saw, which removes the high-quality rubber.

• The Eco Extractor 63’s high-pressure cylinders, unique reverse hook and auto bead ejector capabilities, which require enough force to cut through remaining layers of steel and rubber into smaller more manageable pieces.

The solution to adequately support Eco Razor’s robust hydraulic system was a combination of Parker pumps and motors including the PVplus Axial Piston Pump, which provides the flow for both F12 motorsand a P1 Series 045 cc pump. 

The P1 Series 045 cc pump provides flow to various cylinders used to position the Razor, as the machine works through different areas of the tire. 

For the Eco Extractor, the PVplus Axial Piston Pump with variable displacement is designed and optimized for demanding use in heavy-duty industrial applications. In this case, the hydraulic system required an open-loop pump that could handle a 4,000 PSI requirement. With pressure ratings of up to 420 bar and high-speed ratings, the PVplus Axial Piston Pump’s swashplate principle provides high productivity and power density for this application. 

Because Eco Green selected the F12 hydraulic motors for the Eco Razor, the equipment has the capability, efficienc, and longevity to cut through the mining tires’ tough rubber layers on a consistent basis. Parker’s P1 Series 045 cc pump and PVplus Axial Piston Pump also rounded out the offering for this demanding industrial application.

Eco Green currently has five OTR Mining Tire Solutions being manufactured that will be shipping to Canada, USA, Colombia and Chile over the next few months.

Article contributed by Bill Vetters, applications engineer, for Parker Hannifin Corporation's Hydraulic Pump and Power Systems Division.

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Improving Hydraulic Systems for Better Performance and Energy Efficiency

Wind power generation in the U.S. has been trending favorably upwards for wind farm owners. Primary contributing factors include the cost of wind turbine installations dropping by over one-third since 2010 as the capacity of turbines increased. Add-in the average capacity of turbines installed is now 2.32MW, up more than 200% since the late 1990s. Finally, capacity factors are also rising with an average of 42% reported over the period of 2014 to 2016, a significant increase of 31.5% over the period of 2004 to 2011. American Wind Energy Association (AWEA) reported that in 2019, the industry ended the year with just under 106 GW of operating wind power capacity and nearly 60,000 wind turbines. 

Repowering existing wind turbines with taller towers and longer blades are perhaps the most notable current industry trend. A repowered wind farm not only extends the life of the facility but leverages rising capacity factors found with modern technology along with more efficient power generation. One midwestern energy company, for example, has announced plans to spend upwards of $1 billion to repower 700 existing wind turbines with the promise of 19 to 28% more generation, depending on the farm site. Projections indicate that investment in repowering of existing wind turbine sites has the potential to grow to $25 billion by 2030. 

Download our white paper Increasing Wind Turbine Reliability Through Blade Pitch Control Upgrades to learn about alternative approaches to wind turbine repowering, as more efficient technologies raise wind turbine capacity and reliability.

The development of more reliable and efficient gearboxes has also been the desire of many wind farm owners and the Department of Energy has invested heavily in their development. National Renewable Energy Laboratory (NREL) has also helped develop many new wind turbine components for increased turbine reliability. However, turbine blade pitch control valves, well known within the industry as having a limited life, continue to weigh down wind turbine reliability and capacity.

 

Controlling blade pitch for optimized process speed and product accuracy

Blade pitch control is a critical function within the overall wind turbine control system. Wind turbines operate at constant rotational speed, usually about 15-20rpm for large turbines. The gearbox increases the shaft speed to about 1,000–1,800rpm to match the generator rotational speed requirements, typically producing 60-cycle AC electricity at about 700V. The turbine controller starts the turbine when the wind reaches a given speed, usually about 8-16mph. A yaw drive keeps the turbine pointed into the wind to maximize electricity production.

 

 

The pitch control system, located within the turbine hub, rotates the three variable-pitch turbine blades in unison to precisely control the generator speed based on a feedback signal from the generator. On many of the hydraulically controlled units, there is one pitch control proportional valve per blade on a turbine so, for example, there are three valves used on a three-blade turbine. The pitch system also “stalls” the blades so that there is no lift generated by the rotating blades thus shutting the turbine down when the wind speed reaches about 55mph to protect the turbine from damage. A brake is usually engaged when the blades cease rotation.

 

 

Operational constraints from demanding environments

The pitch control system operates in a very demanding environment and the proportional control valve, one per blade, is arguably the device exposed to the harshest operating environment. Failure of only one of the three valves will force the wind turbine out of service. Data from operators confirm this observation with many field reports of pitch control valve failure within weeks of its first operation, with an unexpectedly large number of failures occurring within six months of service. Upon failure, a maintenance technician must travel to the turbine site and replace the pitch control valve in the hub. Performing this service can take one or more days, depending on the site location, technician availability, and weather conditions. Often the cause of the failure has been traced to circuit board failure due to inadequate vibration protection or the circuit board enclosure design does not prevent dirt and moisture ingress. The cost of a replacement pitch control valve is secondary to the cost of maintenance replacement evolution and the loss of energy generation.

 

Pitch control valves, therefore, must be designed with these specifications to operate 24/7 in an extremely rugged environment:

• Able to withstand heavy vibration, shock, and rotational forces (up to 50G on three axes).

• Valve electronics must be electrically isolated from the turbine nacelle.

• Capable of withstanding extreme cold and heat ambient temperatures.

• Complying with IP65 standards for protection against dirt and moisture, a major cause of valve failure.

 

Raise your wind turbine capacity cost-effectively with new technology

One pitch control valve that has proven itself in multiple wind turbine applications is Parker's D1FC and the D3FC direct operated proportional DC valve with position feedback. The control valves receive an input signal (either 4-20ma or +/-10VDC) from the main turbine controller based on its monitoring of the generator output. Valve flow and performance specifications have been matched to the system requirements of the turbine so as to be compatible with the existing control parameters and co-exist with valves on the other axis.

 

In addition to IP65 designation, which inhibits moisture and dust infiltration, the D1FC and D3FC units are designed to meet IEC 682-6, -7, and -36 vibration standards so that sinus, random noise, and shock loads, respectively, are well accounted for in the design. The electronic driver card is installed with anti-shock mounting technology which minimizes vibrational effects. All fasteners are thread locked to guard against vibration as an additional measure of safety.

 

 

A greater advantage for cost-conscience wind farm owners

A single replacement D1FC valve may be used in conjunction with two existing OEM valves, thereby allowing an incremental replacement program. This approach may be preferable for those owners who would rather replace with upgraded components as repeated failures occur over time. Other wind farm owners may determine that changing all three valves may be the most cost-effective solution when the technician labor cost for multiple repairs and lost generation costs are considered in the analysis.

 

Download our white paper Increasing Wind Turbine Reliability Through Blade Pitch Control Upgrades for a closer look at these alternate approaches, as more efficient technologies raising wind turbine capacity and reliability.

 

Article contributed by Tom Ulery, business development manager, Energy Team Parker Hannifin, North America Wind industry. He has many years of experience in hydraulic valves, as the applications manager for Hydraulic Valve Division. 

 

 

 

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As more OEMs grow in global markets, manufacturers are increasingly seeing the need to incorporate different language options on their displays. With many OEMs manufacturing similar machines across the world, it has become important to have the ability to have an option for different languages on the menu systems and messages. This will ensure that the machine will have a consistent look and feel around the world.

Messages can be displayed in multiple languages for operators to easily understand machine status in their language. Because the display offers an option for language, there can be a one-part number and one software file for the system that can be sold globally. In addition, since there is only one software file, changes, updates, or bug fixes only need to be maintained on one file, not on multiple files.

Getting a product out to market on time and within budget is no easy feat. The PHD application programming tool helps make this a reality by enabling a rapid development environment. The built-in simulator helps test the functionality through the entire design phase, helping to expedite the engineering process and helping to reduce software development costs. New languages can be added simply by passing a language file as an argument to the screen application program.

Having an easy to use programming tool that allows different languages to be easily included is a key element to being able to capture global market share. We've created an example to show how languages can be added easily to the PHD application. The example includes the basic files to get started and shows how to program the PHD display to allow you to change the text dynamically instead of creating a new page for each language, which helps reduce the development time. To support internationalization and broad character support, The PHD Programming Tool uses UTF-8 encoding universally for all text rendering. You will also see that the same page is created only once, but the language of the text can be selected in the application. This helps to shorten development time by allowing the application to be created and maintained once while supporting multiple languages.

Click here to access product information including the application example we just described on the support tab.

Another key feature is the ability to have the screen application separate from the language file. This allows a translator to translate the corresponding text independently from the application software. In addition, the application programmers don’t have to speak any of the other languages that will be used in the applications. This helps reduce development time and cost by allowing the translators to be translators, and not application programmers and the application programmers don’t have to speak multiple languages.

Parker's PHD display family is rugged, general-purpose displays offering full color, a touch-capable screen with built-in CAN, and I/O. For additional information on the display and example applications, please visit http://www.parker.com/phd   

Article contributed by Janaki Viswanathan, regional application engineer, Parker Hannifin Corporation's Electronic Controls Division

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The first hydraulic press may have been invented in the 3rd Century BC, but the fluid power universe has become a little more complicated since then. Today’s hydraulic cylinders, which essentially convert fluid pressure and flow into force and linear movement, are complex devices incorporating a wide range of individual components available in a multitude of dimensions, configurations and materials.

Although pneumatic systems are in some respects simpler, they are generally incapable of achieving the transfer of higher loads and forces. Hydraulic cylinders also have the advantage of smoother, more controllable movement as they are devoid of the spring-like action associated with the release of gaseous fluid media. As an added benefit, hydraulic systems can perform ancillary functions such as lubricating and cooling.

However, since the availability of power and media is a non-negotiable factor in fluid power system design, it should be noted that a properly designed and sized pneumatic system can achieve higher performance where a compact footprint is not required.

Specifying hydraulic cylinders is essentially a balancing act as each design factor influences one or more of the many other design considerations.

Although NFPA standards and ISO-compliant guidelines are a great starting point for hydraulic system design, many industries have guidelines of their own. Working with an engineering manufacturer experienced with all these standards can expedite the design process.

Cylinder manufacturers can offer a range of options capable of achieving the widest scope of performance requirements that increase the likelihood that standard components will meet the design criteria of an application. The major factors to consider when specifying hydraulic cylinders include:

1. Capacity: Medium-duty systems account for most of industrial applications and are typically at 1000 PSI. Standard heavy-duty hydraulic cylinders are capable of handling pressures as high as 3000 PSI, which are typically required for hydraulic presses, automotive applications and other related industrial applications.
2. Stroking distance requirements: Although custom stroke distances above 10 feet (3.05m) are possible. Pressure rating can be a concern. Rod diameter needs to be determined to handle the load.
3. Speed: 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. Frequently, a standard low-friction seal is the better choice for higher speed applications.
4. Temperature: 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). Applications requiring temperature extremes at either or both ends of the temperature spectrum require extensive knowledge of the interdependency of individual components to achieve the best balance of short- and long-term performance expectations.
5. Mounting styles: There are three types: a) Fixed mounts that absorb force along the centerline of a cylinder, b) Fixed mounts that do not absorb force along the centerline, and c) Pivot mounts that drive a load in a curved path.
6. Cylinder bore size: Bore size is related to operating pressure. It is the amount of push or pull force required that determines the bore size needed.
7. Piston rod size: OEM design engineers probably request customization of piston rod sizes more frequently than any other hydraulic cylinder component. Remember to always consider that push or pull is never independent of stroke length when determining rod size.
8. Cylinder configurations: For applications requiring equal force pressure on both sides of the piston, a standard double-acting cylinder configuration using pressure to extend and retract the cylinder, combined with a four-way directional control valve to direct pressure to either the head or the end cap, is almost always preferable to more customized solutions.
9. Rod ends/rod threading: Standard threads can be made in inch or metric format, customization is rarely needed or warranted due to delays, expense and the inability to readily mate with accessory components.
10. Cylinder body tube: Standard cylinder bodies are plain steel or chromed plated and will be able to handle a majority of applications. Using alloy steels, stainless steel or brass materials are prevalent in special application like a water type environment.
11. Stop tubing: Stop tubing is generally used to lengthen the distance between the rod bearing and the piston bearing in order to reduce bearing load on push-stroke cylinders when the cylinder is fully extended. Stop tubing is especially critical for horizontally mounted cylinders where it helps to restrict the extended position of the rod.
12. Seals: Experienced hydraulic system manufacturers will offer seals to meet a complete range of temperatures and fluid types and can help guide an engineer’s specification to meet precise application requirements.

Every industrial application is unique, and there are many ancillary components involved in hydraulic cylinder specification. Energy-absorbing cushions, pillow blocks, regenerative circuits, over- or under-sizing ports — all these and more contribute to optimizing the performance of hydraulic systems, depending on each application’s specific performance requirements.

As with the specification of more fundamental components, selecting appropriate ancillary components can present a specification challenge. For example, cushions are intended to retard the force of motion, but OEM engineers sometimes overlook the fact that fluids are typically not moving very fast anyway and may not require such redundancy in certain types of systems. An engineer may be tempted to take a “belt and suspenders” approach to designing push/pull systems by using cushions with spring cylinder systems, overlooking the fact that the oil needs to work its way through the cap, hoses, valves and so on. In such cases, specifying standard single action cylinders with cushions may be wiser than attempting to insert cushions into spring cylinders.

There are certainly applications for which specifying the right cylinder for the right duty require some customization either in component size, material type or configuration. However, far more often than not, partnering with an experienced hydraulic system solution manufacturer early in the design process will save the OEM engineering team time and money while ensuring the system does its assigned duties as efficiently as possible for as long as possible.

Need help determining the right cylinder for your needs? Use Parker’s easy to use cylinder quoting tool - www.quotecylinders.com.

Article contributed by Jim Hauser, senior engineer, Parker Hannifin Corporation's Cylinder Division

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Properly applied hydraulic cylinders provide outstanding linear-actuation performance in a wide variety of applications. But if applied improperly, a cylinder in short order may not only ruin itself but also the equipment on which it is installed.

There are fundamentally three categories of mounting styles. Both fixed and pivot styles can absorb forces on the cylinder’s centerline and typically include medium- and heavy-duty mounts for accommodating thrust or tension. The third category of fixed styles allows the entire cylinder to be supported by the mounting surface below cylinder centerline, rather than absorbing forces only along the centerline.

There are several available standardized mounts within these categories. Engineers can use this variety of mount offerings for an ever-widening number of application requirements. NFPA Tie rod cylinders, which are used in the majority of industrial systems, typically can 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 of these 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, stabilizing the system and optimizing performance. For rods loaded primarily in compression (push), cap end mounts are recommended; for those in tension (pull), a head end mount is preferred.

It is the amount of tension or compression that determines piston rod diameter; it is the amount of pull or push that 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 its own 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 such a configuration introduces bending forces that can overstress the trunnion pins.

Many performance expectations that at first appear to require atypical mounts can be accommodated by existing styles, sometimes with only slight modifications, facilitating replacement and reducing costs.

One key is to focus on factors that impact cylinder performance. These include the cylinder’s size and force relative to load, the working environment, mounting hardware, and options that prevent wear and improve efficiency. Manufacturers, such as Parker, generally categorize cylinders by the type of action and physical construction. They usually group linear action into these three categories, which directly impacts the mounting options:

• Single acting cylinders provide power only on the extension or "push" stroke.  A separate force, usually an internal spring, returns the piston to its orininal position in preparation for the next stroke.
• Reverse single acting cylinders are similar to single acting, but with the port on the opposite end to provide power only on the retraction or “pull” stroke.
• Double acting cylinders have dual pressure chambers and provide pneumatic power on both extension and retraction, eliminating the need for a spring.

Select the mounting style based on the cylinder’s size, force and function. All these factors are necessary because the wrong mounting or improper installation can side load the rod, which creates excessive wear on the piston, piston rod, rod bearing, and seals. With wear comes leakage, and that is how cylinders fail. 

Regardless of how well a hydraulic cylinder is designed and manufactured, it can fail if not mounted correctly. Proper mounting avoids problems like side loads that cause excessive seal and bearing wear, or even bend the rod or bind the load. 

Contact the Parker’s Cylinder Division or visit www.parker.com/cyl if you have questions regarding which mounting style is right for your application.

Article contributed by Jim Hauser, senior engineer, Parker Hannifin Corporation's Cylinder Divison

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Power Take-Offs (PTOs) provide truck versatility beyond the usual function of providing transportation for materials. Power is directed from the engine to the auxiliary equipment to perform the work. With many applications for PTOs, there are many different PTO designs being developed - each design for its specific application of use. This creates many categories to assist in your search for the right PTO. Below are some of the main filtering search categories and tools that can be used to ensure the correct PTO is chosen for each application.

The variety of transmissions being used in the market today leads to multiple mounting types available for PTOs. The different mounting types can be designed around clearance concerns and assembly arrangements with the specific transmission application.

Depending on the transmission being the PTO is being applied to, there could be a couple of apertures from which to choose. The aperture is the opening on either side of the transmission which permits installation of a PTO. They can be standard or non-standard depending on the transmission manufacturer.

The number of bolts required to mount the PTO to the transmission is one way to classify the PTO. At Parker Chelsea, we have 6-Bolt, 8-Bolt, and 10-Bolt PTO designs. 

We also have rear mount, Ford, reversable and split shaft PTOs. Each one is a category that can be searched in our products tab (parker.com/Chelsea). For the difference of the split shaft PTOs themselves, it is important to note that they are attached within the vehicle’s drivetrain, behind the transmission, and they require special mounting to the chassis frame.

When looking for the right PTO, you must know the make of your transmission. It is an easy and effective way to narrow down your search results quickly. At Parker Chelsea, we use an application guide that allows you to conduct a search based on the transmission manufacturer. From there, you will find a list of transmissions that will lead to pages that show the available PTOs. In our products tab (parker.com/Chelsea), there is a filter in place to search based on the transmission manufacturer.

Chelsea PTOs can be sorted by shift type by using the category filter in the products tab (parker.com/Chelsea). The options in this filter are constant mesh, hydraulic, lever, pneumatic and wire and cable. Constant mesh applies to applications that always require live power and are engaged as long as the engine is running. All others have the ability to be engaged and disengaged.

For an example of a product series to display how a PTO can be categorized in many ways, let’s use Parker Chelsea’s 280 Series PTO. The 280 Series PTO can be found on Allison and other transmission manufacturers. It is a 10-Bolt, hydraulically-shifted PTO. If you are unsure of the information initially, you can visit the product page to learn more about the PTO series. With this information, you would be able to find the PTO series in a product search based on the mounting type under 10-Bolt. For shift type, it would fall into the hydraulic filter. Both of those search results can be filtered down on parker.com/Chelsea.

The driven equipment being used is an important aspect of your PTO selection. While classifying PTO search categories can help narrow down search results, the driven equipment as well will need to be considered when making your final decision. Some helpful information to find the right final product includes the type of driven equipment, the input horsepower required for the driven equipment and the operating speed of the driven equipment. The quick reference guide online provides what information is helpful to know.

You can find different support materials on the website to help learn more about the PTO options available for your application as well as more in-depth information of the PTOs themselves. The products tab, as mentioned, will have the different product category filters to narrow down your PTO search. On the homepage, you can find a competitor interchange tool. if you know of a competitor’s product, and you want to find the Parker Chelsea equivalent, you can learn more on the product page and find similar PTOs of Parker Chelsea. Other support materials to assist in your search can be found on the homepage as well as the support tab: brochures, catalogs, part lists and more. 

Products tab

Application guide

Competitor interchange tool

Quick reference guide

Support tab

This article was contributed by Michael Mabrouk, marketing leadership associate, Chelsea Products Division, Parker Hannifin Corporation.  

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K&B Lumber, a one-stop shop for logging and millwork was in search of a more energy-efficient sawmill that produced higher quality lumber for furniture than a typical sawmill. For most conventional sawmills, the log moves back and forth past the saw and cuts in only one direction. As a result, the operator’s view of the log can be obstructed when it is on the far side of the saw, which can affect lumber quality.

K&B Lumber’s goal was to develop a sawmill that utilized a moving saw, which cuts lumber in both directions and provides the operator visibility to the log while it is being cut. These two features increase the production of high-quality lumber over a traditional sawmill.

K&B Lumber collaborated with Mill Innovations & Design (MID), an original equipment manufacturer of sawmill equipment, to build a sawmill featuring a 6-foot Double Cut HeadRig that was energy efficient and capable of producing furniture grade lumber.

The new HeadRig consisted of a 12” wide band saw with teeth on both edges running on 6’ diameter wheels requiring 250 horsepower (HP). The challenge was finding enough real estate to fit a 25O HP motor on a moving saw.

A second challenge was finding a carriage drive that could accurately control the 30,000 pound saw with a high number of direction changes, 4000+ in an eight hour period. 

Due to the sawmill’s space restrictions with the moving saw carriage, K&B Lumber and Mill Innovations Design chose closed-circuit hydraulics over an electric system to power the equipment.

With a hydraulic system planned, K&B Lumber and MID worked with Parker Hydraulic Pump and Power Systems (HPS) and a Parker distributor to select high-performance hydraulic components to power the sawmill’s saw and carriage drive.

For the saw’s power source, a Parker Gold Cup P14S Pump was selected, driving a Gold Cup M20R Motor stacked with a Parker F12 Series Bent Axis Motor on the back. This powerful combination allowed for additional system displacement.

Using the Gold Cup hydrostat to power the saw, provided the sawmill’s operator the ability to change speeds on the fly, which is critical for cutting different wood species efficiently.

An additional benefit of the saw’s Gold Cup system was a smooth, controlled stop while shutting down the saw voluntarily or in an emergency stop situation.

In terms of the 30,000 pound carriage drive, each direction change means decelerating and accelerating the load in a controlled manner. According to LeRoy Kuhns of K&B Lumber, the Parker F12 Series Motor on the carriage drive has close to a million direction changes and still continues to run flawlessly.

Overall, K&B Lumber has benefited by a smaller, safer sawmill. The new sawmill has also resulted in more efficient energy usage, while producing more output.

In the near future, K&B Lumber plans to enhance their hydraulic system by adding Parker’s Gold Cup - IE (Intelligence Enabled). Gold Cup - IE will monitor their Gold Cup pump to obtain longer service life, and help reduce downtime and service costs with actionable, real-time insights.

Article contributed by Dave Ebert, product manager, Parker's Hydraulic Pump and Power Systems (HPS).

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As mobile machinery makers expand into more global markets, they are presented with the added complexity of creating unique machine configuration for local markets, while still trying to manage the additional costs and complexity resulting from these new machine variations and options. This can be as simple as changing the units from miles per hour (MPH) to kilometers per hour (KPH) and selecting the local language for the text, to complete screen changes to reflect local tastes and requirements, or unique customer interface specifications. These new features can be key to help global machine OEMs capture value in local markets.

One area that can help software teams respond to this demand, is an easy to use programming tool for the display screens. Parker’s PHD display family is designed for use in mobile machinery and offers an easy to use graphical programming tool for faster application development, including:

The WSYWIG environment helps reduce development time by showing the developer how the screens and menus look and feel during the development process, reducing the number of design iterations.

Having no hardware in the loop during screen development not only reduces the complexity of application development but also reduces the time for each design iteration by significantly reducing the hardware download cycle in each design iteration.

Exporting the screens and menu operation to IoS, Windows or Android devices speed up the design review process by allowing a remote stakeholder to view the screen menus and operation with having any hardware or a development license. 

The included image library and the ability to easily import graphic image files helps reduce development time by allowing screen designers to focus on developing the application instead of creating graphics.

Article contributed by Kirk Lola, product manager, Electronic Controls Division, Parker Hannifin Corporation.

Maintaining a normal oil temperature in all hydraulic systems is important for successful system operation. Normal operating temperatures for hydraulic systems is 110 to 130° F (unless specified by the equipment manufacturer). At high temperatures, oxidation of the oil is accelerated. This oxidation shortens the fluid’s useful life by producing acids and sludge, which corrode metal parts. These acids and sludge clog valve orifices and cause rapid deterioration of moving components. The chemical properties of many hydraulic fluids can change dramatically by repeated heating/cooling cycles to extreme temperatures. This change or breakdown of the hydraulic media can be extremely detrimental to hydraulic components, especially pumping equipment.

Overheated hydraulics can be caused by decomposing fluid, wear, or damaged seals and bearings. Coolers can prevent overheating and extend the service life of your hydraulic system. However, smaller hydraulic systems with lower operating temperatures can often be cooled through natural convection. If natural convection is not enough, it becomes necessary to add a cooler.

Coolers are also crucial for systems with temperature requirements such as needing to stabilize the hydraulic fluid’s viscosity by keeping it at a specific temperature, or equipment with a history of hot oil problems that shortened seal life and break down the fluid. Hot fluid is always a concern with large mobile equipment, as well as commercial and industrial processing equipment. Specifying a properly sized cooler saves time, money and maintenance.

The process to select a cooler is driven by the type of system that needs to be cooled. Parameters to consider include heat load, power source, noise, operating costs, space available, environmental conditions, and more.

Actual heat generation varies throughout the machine’s cycles, as well as changing environmental factors and ambient temperatures. This can make it challenging to accurately define your cooling needs. When considering the application and sizing of coolers, the hydraulic fluid’s ideal operating temperature and the time it takes to arrive at that temperature must be used.

For new designs and retrofits, the first step in selecting the right cooler is identifying the challenges and performing the necessary calculations. Virtual design and sizing tools are available from most manufacturers to help determine the best fit for your application. Some companies provide online sizing calculators and other interactive resources that let engineers plug in specifications to get an idea of what is needed. Parker offers a comprehensive suite of online cooler sizing software. For instance, Parker offers an online cooler selector tool for each of the different types of coolers including brazed plate, shell and tube and air-oil coolers.   

To select the best air-oil coolers, you’ll need as much information about the application as possible, including, but not limited to the following:

• Oil Heat Load in BTU/Hr or HP
• Oil Flow Rate (GPM)
• Maximum Inlet Oil Temperature (°F)
• Maximum Ambient Air Temperature During Operation (°F)
• Environmental contaminants that can affect the system
• Maximum Allowable Pressure Drop Across the Cooler (PSI)

If the required heat dissipation is not known, it can be estimated assuming 20-30 percent of the installed horsepower will be converted into heat load. The most accurate way to calculate the heat load is to record the time it takes the oil to get up to temperature without a cooler in the system.

For water-oil coolers, which include Parker’s ST and OAW series coolers, you also need to know the inlet temperature and flow rate of the cooling water. Most manufacturers’ literature includes examples, steps and simplified equations to properly size coolers. For instance, Parker provides engineering specifications for their ST series water-oil coolers, such as cooling capacity, flow rate, working pressure, sizing, and connection thread in their online tools to enhance the specifying process. Once the heat-load parameters and other key influencing factors are defined, the next step is choosing an air-oil (air-cooled) or water-oil (water-cooled) cooler.

Air-oil coolers remove heat from the oil in a cooler by using the ambient air around the cooler. Air-oil coolers convect heat, which makes them ideal when no water source is available or when the preference is to remove heat from the oil by using ambient air. In air-oil coolers, hot oil passes through channels that contain turbulators to prevent laminar flow from developing in an effort to promote heat transfer from the fluid to the channel wall. The channel wall is always constructed of metals with high thermal conductivities.

The cores of air-oil coolers are constructed in two different styles: tube-and-fin or bar-and-plate construction. Tube-and-fin construction consists of round or oval tubes mechanically connected to an array of external fins. The tube-and-fin design is lightweight and offers low pressure drop across the core. The tubes in a tube-and-fin design can be susceptible to damage from pressure spikes and external debris that can be encountered in any application. Bar-and-plate construction uses compact and efficient cores that offer more cooling per cubic-inch than a tube-and-fin design. They consist of finned chambers separated by flat plates which route fluids through alternating hot and cold passages. The bar-and-plate design creates a honeycomb structure that resists vibrations and shocks. This core is usually made of aluminum and is furnace brazed in a controlled atmosphere or high vacuum. With all the bar-and-plate design characteristics that provide certain benefits over the tube-and-fin design, it can be seen that bar-and-plate coolers can offer design engineers greater system design flexibility.

Both types of air-oil coolers typically have a fan driven by a hydraulic or electric motor. Off-road or mobile equipment used in construction, forestry, or material handling typically use either a hydraulic-driven or DC electric-driven fan motors. Industrial equipment such as Hydraulic Power Units (HPU) use AC electric-driven motors to drive the fans. Cooler manufacturers offer a lot of motor configurations, voltages, and displacements to fit various applications. For instance, Parker offers a variety of air-oil coolers with AC, DC, hydraulic fluid, and engine driven fans.  

Cooler manufacturers offer a lot of motor configurations, voltages and displacements to fit various applications. For instance, Parker offers a variety of air-oil coolers with AC, DC, hydraulic fluid and engine driven fans.  Parker’s two most popular air-oil coolers are the ULDC Series (DC fan motor) and the ULAC Series (AC fan motor).

Water-oil coolers remove heat from oil by using a second fluid (typically water). For more than 50 years, shell-and-tube oil coolers have been an industry mainstay when considering water-oil coolers. However, newer designs have been developed that increase efficiency while providing an equivalent heat-transfer surface in a smaller package at a reduced cost.

Shell-and-tube (bare tube) coolers have an outer flanged shell with end bonnets appropriately sealed to each shell end. Inside, a precise pattern of tubing runs the length of the shell and terminates in the endplates. Tube ends are fastened to the endplates, which seal each end of the shell. Cool water flows through the tubes while hot oil flows around the tubes within the shell. The tubes run through several baffle plates that provide structural rigidity and create a maze through which the hot fluid must traverse. This maze created by the baffles lengthens the path the hot oil must flow through. This elongated path increases the amount of heat transfer from the hot fluid to the water by forcing the hot fluid to travel around the tubes for a longer period of time.

As mentioned above, there are shell-and-tube designs in the market now that mechanically add fins to the external surface area of the internal tubes, which increases heat transfer and efficiency. Parker does offer this type of high-efficiency “hybrid” design in the ST Cooler Series. The way the hybrid design works is that the fins add surface area and improve heat transfer, letting the overall size be smaller than standard shell-and-tube exchangers without fins on the tubes (bare-tube). However, due to the increased time the hot fluid has to traverse the interior of the cooler, the pressure drop can be higher than shell-and-tube coolers without the increased flow path created by the baffles.

Another type of water-oil cooler is the brazed-plate style. In this cooler design, heat-transfer surfaces are a series of stainless-steel plates, each stamped with a corrugated pattern for strength, efficiency, and resistance to fouling by creating turbulence in the flow of both fluids. The number and design of the plates varies depending on the desired heat-transfer capacity.

Plates are stacked with thin sheets of copper or nickel between each plate. The plate pack, endplates, and connections are then brazed in a vacuum furnace to join the plates at the edges and all contact points. This design can be used with several different types of inlet and outlet connections.

Brazed-plate coolers are compact, rugged and provide high-heat transfer capacities. They hold approximately one-eighth of the liquid volume of a thermally comparable shell-and-tube cooler. Their stainless-steel construction permits flow velocities up to 20 feet per second. Higher velocities, combined with turbulent flow, provide heat transfer at three to five times the rate of shell-and-tube coolers. A good example of the increased horsepower is Parker’s OAW Series that offers up to 275 horsepower of cooling at an entering temperature difference of 60°F, based on a 2:1 water flow. The higher heat transfer rate requires less heat-transferring surface area for a given capacity.

Due to their compact construction, brazed-plate coolers are ideal when space and size are design requirements. One drawback of using a brazed plate cooler is that there can be higher pressure drops when compared to an equivalent shell-and-tube design. In addition, tests prove brazed-plate designs handle particles up to 1-mm in diameter without issue. Filters or strainers should be used if larger particles will be encountered. Due to their construction, brazed-plate coolers require chemical, rather than mechanical, cleaning.

When properly specifying the right cooler into a hydraulic system, a system will maintain the correct working temperature, which yields numerous economic and environmental benefits, including:

• Extending the hydraulic system’s service life
• Lengthening the oil’s useful life
• Improving operating time and decreasing shutdowns
• Reducing service and repair costs
• Delivering high efficiency for continuous operation
• Resources that simplify the choice

Given the many variables involved when specifying coolers, it is always best to directly contact a cooler supplier such as Parker, with any questions you have. Manufacturers will have additional resources that you can use in the selection process, including specialized sizing software and testing equipment like wind tunnels and cooler design simulation software. Lastly, it is important to take advantage of and rely on your manufacturer’s expertise and available resources to ensure you successfully size and implement the best cooler for your application. To view Parker’s wide range of coolers, visit www.parker.com/ACD.

This article was contributed by Francis C. Gradisher Jr., product marketing manager - KleenVent & Coolers, Parker Hannifin's Accumulator and Cooler Division.

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Cylinders can fail for a number of reasons from wrong specifications to operator error. However, in this day and age with a number of engineering tools available to help reduce spec errors and strong expertise within the fluid power industry, one of the leading causes of cylinder failure is still seals. Whether, the seals are sized wrong, incorrect material is spec’d, or just installed wrong, error in sealing can have a major effect on the entire cylinder operation.

Cylinder operation is based on precise fluid pressure to both sides of the piston. If a seal breaks down and allows fluid to leak from one side of the piston to the other or out of the cylinder all together, the pressures change, and your cylinder will no longer operate as intended. With over 100 years in the fluid power industry, Parker engineers have seen countless examples of how seal issues can escalate into much larger problems for a hydraulic system.

Seal issues tend to fall into three main categories: hardening, bad installation and erosion.

Seal hardening is exactly what it sounds like. The seal can solidify and dry out making it hard and brittle. The most common reason for this is exposure to temperatures that are too high for the seal to handle. Be warned this is not just ambient temperature around the cylinder. The piston itself can generate substantial heat through motion and friction causing wear to the seal. This heat can be monitored by measuring the temperature of the hydraulic fluid entering and exiting the cylinder. There are several methods to combat hardening including insulation and cooling, but the best way is to use materials that are suited for the temperature requirements for your application. Parker offers a number of high-temperature class seals to ensure you meet the heat requirements of your job.

While cylinder operation may seem simple on its surface, it takes precise installation of several parts to ensure that the cylinder will operate correctly for its entire life cycle. The seals are an integral part of this and if they are misaligned it can allow for hydraulic fluid leak past the seals. This can cause problems in cylinder operation that can lead to major failures that will result in costly downtime for your operation. Not only can Parker provide cylinders with the proper seals properly installed, we also offer universal seal kits to help ensure ease of installation on replacements, and our applications engineers have years of expertise to help when these installations get tricky.

Erosion can occur from three main sources. One cause is the general wear from the normal back and forth motion of the cylinder. This source unfortunately is unavoidable but can be prolonged thanks to the developments of Parker's Engineered Materials Group. The Engineered Materials Group develops and manufactures innovative sealing solutions to meet the challenges of today's vastly changing industries. Parker provides a wide range of specialty elastomers to satisfy unique sealing requirements with a combination of experience, innovation and support.

Another source of erosion is pressure build up. If the seal used in a cylinder is not specified to the appropriate pressure, pressure can get trapped underneath the seal and push it against the cylinder body causing wear.

Recently, Parker cylinder engineers identified an issue of a piston seal getting blow by and causing the cylinder to drift in a hydraulic press application.  They were able to identify that the seal thickness was varied from about 1/32” under to almost 1/16” under print dimensions and that there was a slight amount of extrusion on the side of the seal facing towards the cap end of the cylinder. These would indicate higher pressure on the rod end of the cylinder that was getting trapped underneath the seal and pushing it against the cylinder body causing wear. Parker recommended switching from the KP piston seal to the HP that is made of polyurethane, a tougher material, with reliefs molded into the sides of the seal to allow venting excess pressure underneath. This helped the customer identify an issue early that could have grown into a much bigger problem.

The Parker HP energized bi-directional piston seal improves upon the low friction and long wear of lipseals by including excellent low pressure sealing performance. Specially formulated polyurethane is long-wearing and abrasion-resistant with running friction comparable to lipseals. An o-ring energizer ensures virtually zero leakage in low-pressure applications. Also, pressure trapping that can result in energized lipseals is not possible with a single energized seal.

Parker’s HP piston seal is an excellent choice for most industrial applications operating with mineral based hydraulic oil and is available in Seal Classes 1 and 4.

The Parker WP Mixed Media seal is designed for applications requiring different media on either side of the piston. This option is ideal when hydraulic oil is on one side of the piston and air is on the opposite side; and it can be equally effective when dissimilar fluids are on either side of the piston.

Superior low-friction bi-directional sealing is accomplished by combining an energized filled PTFE seal with a redundant elastomer seal. Energizer and redundant elastomer seal materials are available

for compatibility with seal classes 1, 2, 3, 5 and 6. Note: WP piston seal groove is not universal in 1.50" bore.

The final main source of erosion is use with an incompatible fluid. Hydraulic systems use a relatively incompressible fluid, and given the application environment, different types of hydraulic fluids may be required.  For example, use of synthetic hydraulic fluid may be used for highly flammable applications.  That is why you must keep in mind that not every seal will work with every application. If your job calls for a particular type of hydraulic fluid, customers should evaluate the seal material and compatibility to the fluid to ensure they have a seal that will withstand the chemical properties of that fluid. Parker offers seven classes of seals that are designed to work with standard hydraulic fluids to some that are highly corrosive.

Check out the Parker Sealing Technology Bulletin for more information on the wide variety of actuation sealing options Parker can provide. This bulletin shows how Parker seals provide unmatched leak protection on all industrial hydraulic and pneumatic cylinders. It gives ample information to help choose the right seal for your application. Download it now for all your sealing needs.

This article was contributed by Ryan Roberts, market specialist, Parker Hannifin's Cylinder Division. 

Articles of interest:

OEM Design Engineer's Guide to Specifying Hydraulic Cylinders

Cylinder Mounting Styles Vary Based on Performance Expectations

How to Choose the Right Cylinder for the Right Duty

With six decades of experience and hard-earned know-how, Bob Brooks is an expert in residential and commercial site preparation. He began operating equipment at just 14 years old and for the past 40 years he has owned his own business. He has customers throughout the Puget Sound and keeps his calendar full through strictly word-of-mouth promotions. Over the course of his 60-year career, he has utilized a wide variety of attachments — and nothing he has used compares to Parker’s Helac PowerGrip® Multi-Purpose Jaw Bucket in regards to productivity.

At current fuel prices, saving 1/2 gallon per hour adds up to more than $2,000 saved every 1,000 machine hours. Their transportation costs of moving machines between job sites have also decreased by shaving 12,000 pounds off of B and B Excavating’s payload.

Brooks is admittedly tough on his PowerGrip. The sites he clears in the lush Pacific Northwest climate are full of fast-growing evergreen trees, glacial till and more. B and B Excavating previously used cylinder-style jaw buckets and found that they were frequently damaging cylinder-rods and plates when working in rocky soil or digging out concrete foundations. Brooks also disliked the cylinder-style jaw bucket's wasted space in the bucket — with the mounting cross tube on the jaw frequently in his way. With PowerGrip, all the moving parts are fully-enclosed and there are no obstructions in the bucket shell.

While using a thumb combination he grew frustrated by the weight penalty at the end of the boom. B and B Excavating also suffered from inefficiencies like having to take the time to get the bucket under a stump and then pinning the stump with the thumb before working it out of the ground. When grabbing material with PowerGrip, Brooks could just drop down on the object with an open jaw, close the jaw and remove the object. ‘‘PowerGrip offers more control over picking and placing material than anything I have used," said Brooks.

Brooks also values PowerGrip’s ability to seamlessly switch between tasks on the job site. "The PowerGrip really impressed me with its versatility. One minute I am moving heavy boulders or taking down a tree — the very next minute I am grabbing and loading old brittle concrete without breaking it,” explained Brooks.

PowerGrip is equipped with a durable, enclosed rotary actuator hinge that's ideally suited for the toughest conditions. Parker’s Helac rotary actuator hinge technology offers 120 degrees of smooth jaw movement and constant clamping force. The jaw rotation is generated by the massive rotating pivot point between the jaw and back of bucket that’s designed with the Helac sliding-spline operating technology, which converts linear piston motion into powerful shaft rotation. The end caps, seals and bearings work in unison to keep debris and contaminants out of the inner workings of the actuator, prolonging life and reducing required maintenance. High strength, abrasion resistant steel is used throughout for added durability.

PowerGrip buckets are available for equipment between the 4-20 tons class, with bucket width ranges from 24 inches to 48 inches in the trenching and excavating profiles and 48 inches or 60 inches in ditching and grading profiles.

The PowerGrip really impressed me with its versatility. One minute I am moving heavy boulders or taking down a tree — the very next minute I am grabbing and loading old brittle concrete without breaking it,” according to Brooks.  “I’ve used a lot of different hydraulic thumbs and cylinder-style jaw buckets in the past, but to me, nothing on the market compares to the versatility and productivity of the PowerGripl/Multi-Purpose Jaw Bucket.

-Bob Brooks, owner, B & B Excavating

Download the brochure for more information on PowerGrip.   

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

.

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