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The Internet of Things (IoT) is changing human lives and the way companies operate by continuously enhancing how we connect equipment. When the topic of IoT is discussed, the conversation typically centers around cloud computing and big data analytics, but sensors and gateways are just as much at the core of IoT. In fact, sensors are arguably the most critical element in IoT applications since they are the component that makes the devices “smart”. So how exactly do those sensors paired with the other IoT elements such as gateways create a framework that acts as a central nervous system?
Within the vast array of devices that compose the IoT world, there is a growing number of small, sophisticated sensors that together are transmitting signals like those of the human nervous system. In the human body, the central nervous system collects continuous streams of sensory data and transmits that information to the brain, where it is processed. Like the human body, an IoT gateway serves as the connection point between the cloud and controllers, sensors and intelligent devices. All data moving to the cloud, or vice versa, goes through the gateway, which can either be a dedicated hardware appliance or software program.
For instance, for fleet equipment companies, each piece of equipment is part of an entire connected system where the sensors continuously submits and collects data and send it to the gateway to preprocess before it goes to the cloud to be analyzed. To minimize the volume of data that needs to be forwarded to the cloud, an IoT gateway aggregates the data, which can have a big impact on response times and network transmissions, before sending it to the cloud.
As the number of devices and sensors grow in an IoT solution, so does the number of communications that will take place over a combination of public and private networks. Communications between the ‘things’, the gateway and the cloud therefore must be secure in order to prevent any data tampering or unrestricted access. Therefore, the data between the sensors, gateway and cloud is encrypted from end-to-end to preserve confidentiality, integrity and authenticity. In other words, only the IoT device and receiving cloud service hold the cryptographic keys and the gateway acts as an illiterate messenger, passing along messages that it can’t decipher.
A gateway’s role in evaluating system performance and device control
As you can see, within an IoT system the cloud infrastructure is just as important as the devices themselves. IoT devices are no good if they can’t connect to the cloud. For instance, the gateway Parker utilizes for Mobile IoT, is an IoT solution specifically designed for off-road equipment OEMs and fleet managers. This gateway can be used with any J1939 CAN based control system, however, has a high level of integration with IQAN controllers for a user-friendly experience. By utilizing this enhanced gateway, our Mobile IoT solution connects data from off-road equipment to a secure Parker cloud and then presents information through an easy to configure interface that delivers advanced insights and data-driven value. These insights have the potential of helping users avoid unplanned downtime events through continuous monitoring with the use of alarms or analytical models.
So, whether you are connecting legacy devices or new devices to your IoT ecosystem, an IoT gateway does have a very important role to play when connecting data to the cloud.
Article contributed by Clint Quanstrom, IoT general manager, Motion Systems Group, Parker Hannifin Corporation and Kyri McDonough, marketing communications manager, Parker Hannifin Corporation.
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Electrically conductive plastics continue to provide reliable EMI shielding in a wide variety of applications. Specifically, thermoplastics can overtake bulky metal enclosures due to their superior weight, EMI shielding capabilities, and simpler manufacturing process. However, before purchasing any thermoplastic, it is important to consider performance capabilities.
Single pellet vs multi-pellet dry blendElectrically conductive thermoplastics are typically sold as a pellet blend of two or more components, made up from a variety of base polymers and stainless steel pellets. In small applications and sizes, these blends can generally be effective but are always bound to have consistency issues. In transportation and handling the stainless-steel pellets will settle to the bottom, resulting in an inconsistently shielded final product. This problem becomes more evident when molders run large quantities of parts and when they store the mix in large containers.
Selecting a one pellet plastic material, like Parker Chomerics PREMIER PBT 250-FR, eliminates this problem, since there is no mixing of pellets. Instead of having stainless steel pellets as a separate component, stainless steel fibers are pultruded into the plastic pellets to provide shielding. Single pellet thermoplastics can be sold in large quantities, unlike pellet mixes.
Different types of flame retardant ratings
Understanding the plastic’s UL 94 rating will help determine how it will perform under fire hazard conditions. In order to receive the UL 94 5VA certification, the plastic must stop burning after 60 seconds on a vertical plaque, with no drips or holes, according to the UL website. This rating, is the highest level of flammability resistance for any thermoplastic. The next rating down, UL 94 V-0, means the plastic can stop burning within 10 seconds on a vertical specimen and the drips are non-flammable. Most thermal plastics that are electrically conductive fall under the UL 94 V-0 rating and require an extra coating to be EMI shielded. But Parker Chomerics PREMIER PBT 250-FR earns a 5VA rating at 2.5 mm thickness without the need of a coating to achieve electrical conductivity.
Compared to metal enclosuresIn addition, plastics can also be more cost effective than metal enclosures. Although metals are typically more cost effective initially, the secondary machining requirements of
many metal components can add significant cost and lead time. For example, many die cast parts require machining operations to drill and tap threads while most thermoplastics can be molded with pre-formed holes and use thread forming screws. Also, plastics are significantly lighter than metal enclosures, helping to better achieve light-weighting goals.
ApplicationsParker Chomerics PREMIER PBT 250-FR, a single pellet UL 94 5VA electrically conductive thermoplastic, is known for its excellent performance where petrochemical exposure is common. Typical applications include retail fuel dispenser pumps, housings, dispensers and face plates, electronic payment terminal housings, security access points, and more.
This blog contributed by Page Ludl, marketing co-op, Chomerics Division.
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Conventional buildings, and the construction process that creates them have a substantial impact on the health and wellbeing of people and the planet. They’re costly to maintain and operate, generate waste that can have a significant impact on local environments and nature, and use global resources to construct and operate. In fact, it has been estimated that the daily operation of buildings accounts for 40% of total energy usage worldwide. Now, enter the world of green building.
Commercial green building is on the rise--and keeps growing
Green building is the practice of designing, constructing and operating buildings to maximize occupant health and productivity, use fewer resources, reduce waste and negative environmental impacts, and decrease life cycle costs.
How big is the movement? It’s big. Building owners expect to build more than 60 percent of their projects as green buildings by 2021. Decreased operating costs, short payback periods and asset value increases were strong drivers of green building, but creating healthier indoor environments was also a major motivator.
In addition, a rating system such as LEED allows builders to create a better-performing building. LEED, or Leadership in Energy and Environmental Design, is the most widely used green building rating system in the world. It’s a system that’s now broadening its focus on construction to include maintenance and the long-term sustainment of energy efficiency.
Download our white paper, How to Capitalize on HVAC/R Trends to Drive Business Growth and learn what actions contractors and distributors must take now, to capitalize on environmental responsibility trends.
The key to meeting greenhouse gas targets
Lowering a building’s initial energy consumption is critical to meeting greenhouse gas targets. On the maintenance side, energy savings alone from properly maintained building systems could be 2 to 5 percent or more. From a greenhouse gas standpoint, consumption is 95 percent of the impact of an air conditioning/heating operation. Properly maintained systems perform much better. Refrigerant leakage is prevented but also prevents consumption.
With LEED recertification programs now focused on upkeep, HVAC and refrigeration system maintenance professionals have an opportunity to play a bigger role with facilities managers and/ or building owners. One way to take advantage of that opportunity is by becoming a GreenSTAR.
The Mechanical Service Contractors of America, or MSCA, created the GreenSTAR program in response to the demand for LEED certification in commercial buildings. Taking a “whole building” approach like LEED, GreenSTAR contractors view buildings as an ecosystem – people, air, water, equipment, and systems all operating together to maximize environmental quality and return on investment while minimizing resource use.
Proactive vs. reactive approach to GreenSTAR certification
Getting GreenSTAR certified is a tangible way for HVAC industry professionals to demonstrate to clients their credibility and expertise in environmental stewardship.
GreenSTAR Certification:
Provides an opportunity to stand out from the competition and be an industry leader.
Illustrates commitment to ongoing green building training and education.
Demonstrates proven LEED experience.
Highlights an understanding of equipment upgrade and energy efficiency issues.
Clients working with GreenSTAR companies benefit from reduced energy costs, improved air quality and water efficiency, greater employee productivity and satisfaction, and assurance that all federal and local environmental regulations are met.
Green building is penetrating the residential world, and fast!
One major green home change that will impact contractors is the new standard for furnace fan efficiency ratings, effective in July of this year. For residential furnaces, that means an industry-wide transition from PSC (permanent split capacitor) motors to more efficient EC (electrically commutated) motors. The U.S. Department of Energy believes the new standard will save Americans more than $9 billion in home electricity bills through 2030.
Business opportunities abound for the HVACR industry
Clearly, green building – both residentially and commercially – holds sustainability options and numerous opportunities for both HVACR contractors and distributors.
Download our white paper, How to Capitalize on HVAC/R Trends to Drive Business Growth and learn what actions contractors and distributors must take now, to capitalize on environmental responsibility trends.
Article contributed by the Parker Global Team.
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In our July Semiconductor entry, we noted that lowering the cost of ownership is a multi-faceted goal. We discussed how one of the areas for potential improvement is mechanical design and how the Parker EZ-Lok seal is a major solution to mechanical seal failure. In this entry, we’ll investigate a notably different type of cost-reduction opportunity – material selection – and see how Parker’s innovative HiFluor compounds can reduce seal costs to as little as half.
Critical EnvironmentsWhen it comes to the seal industry, the semiconductor market is well known as one where the most premium, chemical-resistant compounds are a necessity. Microelectronic manufacturing processes involve chemistries that push the limits of what elastomeric compounds can withstand in terms of both chemical aggressiveness and variety. The perfluorinated materials (FFKM) capable of withstanding these environments require intricate manufacturing processes regulated by closely-guarded trade secrets and the significant investment of resources.
These factors drive the price of FFKM compounds to the point of being as much as 50 times the cost of any other variety. Cutting just a slice out of this cost can result in significant savings – a chance to take out a quarter or even half the pie would be advantageous indeed. Fabricators should be continually on the lookout for more cost-effective compounds that show equal performance in their pertinent operations.
This is why Parker’s HiFluor compounds offer an opportunity for cost savings that shouldn’t go unnoticed.A unique hybrid of performance between FFKM and the simpler technology of fluorocarbon (FKM) elastomers, HiFluor offers the most superb chemical compatibility in the many semiconductor environments where the high temperature ratings of FFKM aren’t necessary – and at a fraction of the cost.
Not only can HiFluor be used where even FKM is lacking, but its performance in applications with aggressive plasma exposure is spectacular as well. This can be observed by its overall resistance to plasma-induced material degradation. However, Parker has also developed multiple formulations that display extremely low particle generation when most materials would be expected to suffer severe physical and chemical etch.
Solutions and Cost Savings
Need assistance deciphering exactly where this kind of cost-savings can be implemented? Parker O-Ring & Engineering Seals Division has all the resources needed to help their customers identify opportunities to utilize HiFluor seals.
For instance, one major semiconductor fab had several factors (other than their seals) dictating the frequency of their preventative maintenance (PM) intervals. The fab wanted to replace their seals at these intervals as a precautionary measure to limit the chance of them becoming another PM-increasing factor. However, this caused these premium FFKM seals to be a source of inflated cost. Parker engineers assisted with a process evaluation that resulted in over half the seals being replaced with cost-effective HiFluor O-rings, while the tool regions with more intense plasma exposure were reserved for the elite performance of Parker’s FF302.
Another major fab in the microelectronics industry switched from FKM to FFKM seals in their oxide etch process. The tool owner achieved the desired performance improvement, but soon began searching for less expensive options. Based on guidance from Parker engineers, he recognized the plasma resistance and low particulate generation of Parker’s HiFluor compound, HF355. After implementing this change, he retained the performance improvement, but at a fraction of the cost.
Semiconductor tool owners understand that their aggressive processes require the most robust, expensive FFKM seal materials. The price tag on these seals is greater than those from any other compound family. Fortunately, HiFluor is a proven sealing solution that can bridge the gap and provide the same kind of high performance at a much lower cost. To find out if HiFluor is right for your application, visit us at Parker.com/oes and chat with and engineer.
This article was contributed by Nathaniel Reis, applications engineer, Parker O-Ring & Engineered Seals Division.
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Simple maintenance steps for system reliability
There are simple steps that an HVACR technician can take during their routine spring and fall inspections or at any time when onsite to enhance reliability. The good news is that most of the items listed below are commonly followed for system efficiency and capacity maintenance but also positively affect system reliability. Performing these simple steps greatly enhances the probability that a system will last its full design life.
For more information on sizing filter-driers and system clean-up procedures please see Parker Sporlan Bulletin 40-10. For various HVAC and Refrigeration product information visit www.Parker.com/Sporlan.
Article contributed by Glen Steinkoenig, product manager, Contaminant Controls, Sporlan Division of Parker Hannifin.
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Single-use solutions have been widely adopted on a global scale within the biopharmaceutical industry due to the many advantages and process improvements they offer.
Key applications for single-use assemblies include the creation of process fluid flow paths, buffer/product storage solutions and sampling systems on varying scales.
Most of these systems will start with either a bioprocess container or a tubing option and require the ability to connect to further pieces of equipment or additional single-use systems/manifolds.
In order to achieve this connectability, some form of connection needs to be selected — but with so many different connection types available, where should biopharmaceutical manufacturers start?
There are many different options available when embarking on the selection process. Consideration must be given to whether the connection type needs to be aseptic to provide quick and easy sterile connections, (even in non-sterile environments) or non-aseptic (to provide quick and easy non-sterile connections).
How do you choose the correct option?
The choice should be guided by the process itself — and the capability of the manufacturing plant should also be taken into account.
Key factors which will determine the correct choice of connection type include:
Only when these factors have been addressed can the end-user begin to fully specify the connection type required.
Connection types The Luer connector
The Luer connector is the simplest connector. It consists of both a male and female form, and the connection is made using a twist-lock action. These connections are suited to sample lines (with syringe connectivity) and low flow narrow-bore tubing applications and can be used within a laminar airflow hood to create aseptic connections.
However, there is a downside: potential misconnections can occur when they are not mated correctly.
Quick connectorQuick connectors such as the MPC, MPX or MPU from CPC (Colder Products Company) are similar to Luer connectors in that they can be used within a laminar airflow hood to create aseptic connections. They have the added security of a push-fit feature with a secure locking mechanism.
TriclampTriclamp (sanitary style) fittings can be used as connectors. While these are effective and secure connections, care must be taken to position the required o-ring seal within the connection prior to fixing the connection using an external clamp. The sheer size of the external clamp may make this an unsuitable method for connecting narrow bore or thin-walled tubing due to the weights involved and the potential for kinking/doubling of the attached tubing. Triclamp connections can be used within a laminar airflow hood to create aseptic connections.
Connections outside of a laminar airflow hood
Should aseptic connections be required to be made outside of a laminar airflow hood, two options are available, which both allow the connection of varying tube sizes:
Gendered aseptic connectorThe first option for connecting aseptically in a non-aseptic environment would be to use a gendered aseptic connector, such as CPC AseptiQuik® gendered, which has both a male and female version. The benefit of using a gendered connection is that it can help by safeguarding which lines can be connected to certain points in the process; this helps to mitigate against human error and the accidental connection of the incorrect lines/equipment.
When designing single-use assemblies using a gendered connector approach, care must be taken to ensure that the correct male / female side is designed into each part; this in itself can also create some areas for error to creep in.
Genderless aseptic connectorShould the end-user not have any concerns over an accidental connection to the incorrect lines/equipment, or simply want to remove the error of male/female connector type which can creep in during design, there is the genderless aseptic connector, such as CPC AseptiQuik® genderless. These connectors take out the requirement for designing in the correct male/female orientation and can enable universal assemblies to be manufactured and connected with many other assembly/equipment types.
Both gendered aseptic connectors and genderless aseptic connectors operate via a mechanism that enables connection in non-sterile environments to be made possible. This is because of the use of proprietary seals which mate together before a protective seal is removed, thus keeping the process stream in its aseptic/sterile condition.
Connecting stainless steel and single-use
Should sterile connections between traditional stainless steel biopharmaceutical processing equipment and single-use assemblies be required, there is another option:
Steam-to connectorsSteam to connectors, such as CPC Steam-Thru®, work by allowing steam to pass through the section connected to the stainless steel equipment. Once steamed and connected, a valve within the connector is manipulated, creating a sterile or aseptic flow path.
Conclusion
It is apparent that there are many connections capable of creating or maintaining an aseptic/sterile environment, but without the correct process condition assessment, operator care or design considerations, biopharmaceutical manufacturers could be looking at a costly connection failure.
Download our white paper to find solutions to more single-use challenges: Single-Use Technology: The Next 5 Challenges to Conquer
This post was contributed by Graeme Proctor, product manager (single-use technologies), Parker Bioscience Filtration, United Kingdom.
Parker Bioscience Filtration specializes in automating and controlling single-use bioprocesses. By integrating sensory and automation technology into a process, a manufacturer can control the fluid more effectively, ensuring the quality of the final product. Visit www.parker.com/bioscience to find out more.
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The U.S. Census Bureau estimates there are more than 100,000 car wash facilities throughout the country with Americans spending $5.8 billion annually to have their vehicles cleaned and detailed. In fact, over the last two decades, the number of car owners opting for car wash and auto detailing services has increased exponentially, and industry revenue growth is forecasted to grow at an average yearly rate of 3.3 percent. This will continue to rise as automatic car washes become more affordable and environmentally friendly.
With tremendous growth comes increased competition to provide the most convenient and specialized car wash process for the modern vehicle. For decades, full-service, in-bay automatic (IBA) and self-serve car wash services dominated the landscape. Today, they are competing with express exterior and flex-serve washes implementing modern systems and processes that greatly enhance the car wash experience for a better and longer wash while utilizing virtually no labor.
Performance problems that can wash away businessMachines are the lifeblood of modern professional car wash facilities. Success is dependent on the performance of the equipment. As the demand grows for vehicle washes, system components are being used at a much higher pace and volume which can result in faster wear and tear of machinery. Automated conveyors, for example, can fail to operate on high traffic days due to insufficient pressure issues. If mechanical problems persist due to poor performance, this may lead to car wash downtime resulting in a huge loss of profit.
Along with machines, car wash owners and operators must be mindful of car care applications. Modern chemical systems are essential to wash performance. Running out of soap or wax can also lead to downtime. The ability to monitor liquid levels can ensure the car wash process is performing at an optimum pace. These liquids can also be affected by variables beyond control, such as the weather. The most important agents, soap and water, under the most extreme conditions can induce havoc on a car wash facility. Car washes can shut down from frozen waterlines, ice buildup, bay door malfunctions or equipment freezes. Being offline temporarily can have permanent consequences for owners and operators.
Despite industry advancements, car washes remain subservient to other variables such as air pressure and water temperature. Innovations in advanced condition monitoring and the advent of the internet of things (IoT), equip owners with data and analytics to diagnose machine health, detect issues before they arise and monitor equipment in all weather conditions.
Condition monitoring for car wash facilitiesOne car wash equipment manufacturer for automotive dealerships wanted to provide preventative maintenance on its systems. They were seeking a remote monitoring solution that would allow them to monitor a variety of conditions:
Real-time information would enable technicians to effectively and efficiently service equipment. Additionally, the capability to sense chemical levels would allow owners to know exactly when soap, conditioner, pre-soak and other cleaner replenishments need to occur, reducing system downtime and lost revenue.
Preventive maintenance ensures continuous operations and machine performance
The local Parker distributor suggested a continuous remote monitoring solution that could monitor the system including liquid level sensing. SensoNODE™ Gold Sensors and Voice of the Machine™ Software is a low-cost monitoring system with superior flexibility that can be incorporated throughout the car wash process in new or existing systems. By installing the wireless SensoNODE Gold Sensors, service technicians can monitor the bay for changes in pressure, temperature and humidity with instant data and conduct accurate diagnostics to pinpoint any potential issues without having to be on-site.
Chemical levels can be tracked with Parker’s liquid level sensor which identifies chemical fluid levels within barrels. This sensor is non-invasive and attached to the outside of the chemical container. This reduces the opportunities for spillage and employee health mishaps. This helps alleviate material and equipment issues while also providing service technicians with critical information to know exactly when they are needed to be on location.
Together, SensoNODE Gold Sensors and Voice of the Machine Software create a touch-free experience for the dealership as up-to-date machine measurements and chemical levels are available to be viewed via an internet connection. Access to this information eases concerns over inadequate car washes, equipment malfunctioning or low chemical levels. Learn more.
Article contributed by Westin Siemsglusz, IoT market sales manager, Parker Hannifin Corporation.
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It's no surprise that electronic enclosures and housings in aerospace and defense applications are built to meet the most stringent of military standards. These include but are not limited to environmental stresses, EMI shielding, and maintenance requirements. Additionally, the advanced technological requirements of the devices requiring these enclosures mean that these devices must be more rugged and more powerful, as well as smaller, lighter, and easier to replace.
This poses challenges for designers, leading them not only to suppliers who can meet these requirements but partners who can assist in the design and supply chain management of these complex units.
For environmentally-sealed and EMI-shielded electronics devices, there is no better full-system solution than an overmolded or vulcanized cover.
So, what is overmolding/vulcanizing/mold-in-place gasket anyway?
Top 6 benefits of overmolded covers with conductive elastomers
With more than 40 years of experience in overmolding, the Process Engineering team at Parker Chomerics can assist with full system enclosure design that takes into consideration such factors as ideal surface finish and groove dimensions to meet customer-driven requirements. We will work with customers to determine whether overmolding is the best solution and feasible based on all necessary specifications.
Supply chain partnership
As devices become more complex, so do the associated supply chains. An electronic enclosure can quickly pick up more than 5 or 6 individual suppliers, each needing to meet various requirements of military standards. In addition to the difficulties of sourcing the best suppliers, a complicated web of interdependent timelines starts to appear. This is where Chomerics can provide significant support and logistical relief. Parker has an extensive network of first-class suppliers and can also work with customer-approved suppliers to manage a project from start to finish. Services offered can include: overmolding, machining, painting, dip brazing, embedded fasteners, part marking, etching, and custom packaging.
Overmolded covers provide countless benefits for customers looking for the best solution to durable and reliable EMI shielded, environmentally sealed housings while minimizing a complicated system of suppliers.
This blog post was contributed by Ben Nudelman, market development engineer, Chomerics Division.
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Over the past few years, market demand has increased for mobile equipment that is powerful and more efficient. In response to this trend, an OEM of sugarcane harvesters began a redesign of their equipment. Previously, less efficient gear pumps were used in their hydraulic systems. This presented an opportunity to increase machine efficiency and productivity while reducing fuel consumption. The goal was at least 10% to make their product more attractive to end-users. The OEM consulted with Parker’s Global Mobile Systems (GMS) team to create a new hydraulic system that would meet their new performance goals.
GMS completely restructured the hydraulic system by switching to a variable displacement open circuit solution, using P1 Series pumps with Electronic Displacement Control (EDC) and F12 Series bent-axis piston motors. This compact electronic solution reduced system complexity and increased efficiency; which reduces operational costs over the machine’s lifetime. Open circuit EDC was chosen due to charge pump losses in a closed circuit solution and extra components needed for a load sense system. The system design also reduced the number of potential leakage points while providing better pump response and on-board diagnostics. Multiple P1 Series pumps were incorporated into the hydraulic circuit for different functions including the primary extractor, base cutter and fan drive.
The P1 Series was chosen because of its high efficiency and power density. This dynamic combination enables high-efficiency power management by limiting torque to the current load requirements. By optimizing flow output at different pressures and speeds, the engine uses less fuel and produces less heat. This P1 was also equipped with a displacement sensor that monitors in real-time the angle of the swashplate. This allowed the customer to achieve a more accurate flow output by closing the electronic loop via the sensor feedback giving them the ability to regulate overall vehicle power consumption more effectively. The P1-045 used for the cooling system also features ripple chamber technology, which reduces noise and pressure pulsations.
The lightweight, compact F12 Series bent-axis piston motor features a unique, lightweight spherical piston design, which provides high efficiency, speed, and acceleration capabilities. The result is unmatched power density with less heat generation. The F12 is utilized on the fan blower to convey leaves and stripped chaff out the rear of the machine.
Measuring equipment performance
The results of the system yielded lowered fuel consumption by more than 10 percent which exceeded the original goal. Additionally, the system saved costs by simplifying the hydraulic system and reducing the number of components. It also provided improved pump flow response and upgraded control versatility and stability that contributed to improved machine productivity.
The GMS team works directly with their OEM customers as trusted partners in developing innovative solutions. By understanding customer goals, needs and expectations, Parker delivers value by improving the bottom-line and increasing machine performance.
For more information on how to improve your hydraulic system, email us or visit us at www.parker.com/hps. Your pump will thank you.
This article contributed by Keith McDonald, product manager, Parker Hannifin Corporation Hydraulic Pump and Power Systems Division.
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Closure force requirements are an important consideration for sealing applications, and the Applications Engineering team is often asked for guidance as to how to minimize or predict the amount of force it will take to close a properly-designed face seal groove.
There are several factors to consider when trying to determine compressive load. The most important of those considerations are:
Hardness of the rubber
It is correct to assume that as the hardness of the rubber increases so too does the compressive load. Parker’s O-Ring and Engineered Seals Division offers materials that cover a range of 40-95 durometers (Shore A scale).
Below is an example of compressive load for a 0.139” CS O-ring made from NBR (Buna-N) materials at different measures of hardness (60, 70, and 90):
Figure 1: Measure of compressive force requirements of a 0.139”CS, NBR material at different hardness levels.
Cross sectional thickness
Another intuitive thought is that as cross-section diameter increases, so does the compressive load requirement.
Below is a plot of compressive load requirements per linear inch for the standard cross sections (0.070”, 0.103”, 0.139”, 0.210”, and 0.275”), and it follows that logic.
Figure 2: Compressive load requirements at different cross-sectional thicknesses on a 70 durometer NBR material.
Groove width
Groove width impacts compressive load because of how it changes the amount of gland-fill in a given application. If a groove is narrow, the O-ring is likely to make sidewall contact once compressed. When sidewall contact occurs, it results in higher compressive load requirements because of how the part is being constricted in the groove. If there is an application that has high gland fill, adding a draft angle can significantly reduce the compressive load requirements, as shown in Figure 3. Figures 4, 5, and 6 show the impact of groove width and draft angle on gland fill.
Figure 3: Compressive force for 0.070" CS 70 Durometer NBR at 99.8% nominal gland fill when fully compressed. The graph shows the impact of draft angle on compressive load for grooves that have very high gland fill.
Figure 4: This image shows an O-Ring being compressed with no sidewall contact.
Figure 5: This image shows an O-Ring being compressed the same amount as in Figure 4, but with a narrower groove. The result is very high gland fill.
Figure 6: This is the same amount of compression as in Figure 5, but with a 3-degree draft angle added. The result is lower gland fill and lower stress on the O-Ring.
Material familyA common myth in the sealing industry is that there is a correlation between material family and compressive load requirements, but as seen in the graphic below, that is not the necessarily the case. The only truly accurate statement is that silicone materials have lower compressive load requirements than that of other materials. Otherwise, many material families have significant overlap in the amount of compressive load they generate for the same amounts of squeeze.
Below is a plot of compressive load requirements per linear inch for various 70 durometer materials.
Figure 7: Compressive load requirements by material family with hardness held at 70 durometer.
In summary, here are some ways to mitigate high compressive loads without sacrificing the amount of squeeze applied to the seal:
• Use a softer (lower durometer) material.
• Use a thinner cross-sectional diameter.
• If gland fill is very high, widen the groove. If that is not possible, consider adding a draft angle.
• If appropriate for the application, switch to a silicone seal material.
• If the application is conducive, consider using a hollow cross section from our extruded product line.
This article was contributed by William Pomeroy, applications engineer, Parker O-Ring & Engineered Seals Division.
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Incorrect installation of a Power Take-Off (PTO) may cause the PTO and/or the gearbox to break and damage other parts as well as cause death, personal injury and property damage. Therefore, PTOs should be mounted by qualified personnel with suitable tools and measurement instruments by carefully following the installation guidelines. The specific guidelines are similar no matter the manufacturer and include the following takeaways:
A power take-off must be properly matched to the vehicle transmission and to the auxiliary equipment being powered. An improperly matched power take-off could cause severe damage to the vehicle transmission, the auxiliary driveshaft, and/or to the auxiliary equipment being powered. Damaged components or equipment could malfunction causing serious personal injury to the vehicle operator or to others nearby.
To avoid personal injury and/or equipment damage always refer to Chelsea catalogs, literature, and owner’s manuals and follow Chelsea recommendations when selecting, installing, repairing or operating a PTO which can be accessed on our website.
This article was contributed by Michael Mabrouk, marketing leadership associate, Chelsea Products Division, Parker Hannifin Corporation.
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In the biopharmaceutical industry, extractables and leachables have come under the spotlight as stainless steel manufacturing systems have given way to single-use assemblies in manufacturing operations.
Yet, there is some confusion as to what the terms 'extractables' and 'leachables' actually mean. They are often talked about interchangeably, but there are actually distinct differences between the two.
Extractables studies are an assessment performed on a material. They are performed to identify substances that a patient may be exposed to and are typically conducted using 'worst-case' conditions.
Leachables studies are an assessment performed on the drug product to identify substances that patients are potentially exposed to and are typically conducted using 'true process' conditions.
Learn about different approaches to extractables and leachables testing in our white paper: Demystifying Extractables Testing
So why are extractables and leachables so important?Due to the nature of plastics and the potential release agents and plasticizers used in their manufacturing processes, there is potential for some of these to be released into the biopharmaceutical process stream.
In a single-use assembly, numerous components have the potential to contribute to extractables and leachables. These include tubing, connectors, bags, bottles and filters. Therefore, the whole assembly should be assessed collectively.
Every plastic will have some degree of compound leaching or release, but each compound may not be given equal importance with regard to what is allowed or is applicable to the process stream.
As there is no 'one size fits all' with regard to what is and isn't allowed for many compounds, end-users need to assess the risk based on a number of factors.
Risks and assessment can be categorised into:
Vendors usually take on the responsibility of performing extractables studies, while end-users taken the leachables part - as these studies should be conducted using 'true process' conditions. However, there remains some confusion over what a vendor should provide.
In our Demystifying Extractables Testing webinar, we asked participants what their expectation was of a single-use vendor's role in extractables and leachables studies.
While more than 70 percent of respondents believed that the vendor could only offer extractables data, more than 20 percent responded that both extractables and leachables data should be supplied by the vendor. However, leachables data needs to come from a true process stream that only the end-user would have access to.
The vendor would take the following steps:
The vendor would then either perform their own extractables study, or obtain the extractable data set from their supply chain in order to identify 'worst-case' released compounds under extreme conditions.
The outcome from the vendor's point of view would be to:
The customer would take the following steps:
Selection of component parts - customers may have experienced negative effects on their own processes with specific components used within singe-use assemblies. This may inform their choices
The process would then be mapped out to ensure that all components are compatible for their intended use. The next step would be to take the 'worst-case' extractables data from the vendor and risk assess this based upon knowledge of their process.
This helps the customer understand how componentry will behave, but to satisfy regulatory bodies, further 'leachable' studies may need to be performed using the actual process stream intended for use with the assembly. There is generally more process risk from extractables and leachables as the process progresses. Released compounds early in the process may be removed through processing steps, but as the process reaches its final formulation, the risk attached to any released compounds present exponentially increases.
The outcome of this data generation from the customer's point of view would again be to:
It is vital that there is clarity across the biopharmaceutical manufacturing industry on the importance of extractables and leachables studies and who should carry out the studies. And, while both vendors and customers may have different reasons for carrying out testing, the end goal for both parties is the same.
Learn more about extractables and leachables testing in our white paper: Demystifying Extractables Testing
What approach does your company take to extractables and leachables testing? Let us know in the comments below.
This post was contributed by Graeme Proctor, product manager (single-use technologies), Parker Bioscience Filtration, United Kingdom.
Parker Bioscience Filtration specializes in automating and controlling single-use bioprocesses. By integrating sensory and automation technology into a process, a manufacturer can control the fluid more effectively, ensuring the quality of the final product. Visit www.parker.com/bioscience to find out more.
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Today, cement manufacturing plants have to contend with a double-edged sword: How do they reduce production costs and still meet environmental regulations? How do they accomplish their goals and directives while maintaining their equipment in a manner that prevents unscheduled downtime and hazardous conditions? Reducing the cost of fuel is a common strategy employed within the industry; in turn, this has led to an increase in the substitution of coal with petcoke.
One area that has been impacted by the use of petcoke is the coal mill dust collector. Coal mill dust collectors have a substantial effect on productivity, yet have received relatively little attention as companies implement cost-saving programs, like the use of petcoke as a fuel reduction measure. Petcoke is typically ground finer than coal, and it has a particularly sticky nature that makes it more difficult to clean from filter bags. Its high sulfur content increases the likelihood of corrosion. All of these things bring into question whether the dust collector in use is properly designed for the conditions and if the operation and maintenance plan is effective in preventing system upsets and safety concerns.
Here, we'll discuss effective design, operation and maintenance tips for this critical component of the coal grinding circuit and what you can do to evaluate the readiness of your coal mill dust collector.
How to keep your dust collector operating at peak performance
Dust collector operators must take into consideration these items as they evaluate their current equipment design:
An air-to-cloth ratio that does not exceed 3.5 ACFM per 1 square foot is recommended to prevent short filter life, high differential pressure, higher emissions and operating costs.
An undersized system can cause an excessive buildup of combustible material on the filter bags. The use of single diaphragm pulse valves or valves that are smaller than 1.5 inches often requires an upgrade.
Defined as the upward velocity of dust-laden gases between filter bags, excessive can velocity can result in higher pressure drop and excessive dust accumulation. For a coal mill dust collector, velocity should not exceed 240 fpm or 1.22 m/s.
Filter bag selection
Polyester, acrylic and aramid filter bag fabric materials require a dust cake for fine particle filtration. This can lead to an increased risk of combustion. Opting for an ePTFE membrane material, like the BHA Preveil filter from Parker Hannifin does not require a dust cake, reducing the combustion risk.
BHA Preveil filters are made from PTFE resin, a substance with inherent non-stick properties that can be used to help your dust collector operate at maximum efficiency by providing:
Proper inlet design distributes gas flow evenly and eliminates abrasion issues, which cause holes in the bags and increased emissions.
A steel, air-tight housing and hopper, free of shelves or other particle accumulation areas, equipped with level and temperature measurement devices is recommended to prevent hazardous conditions. To avoid buildup of combustible materials, hopper walls should be designed with a minimum angle of 70 degrees from horizontal.
A lack of insulation can result in moisture and accumulation of combustible dust. When petcoke is used this can also result in the increased formation of sulfuric acid and eventual corrosion of the dust collector.
It is essential that material handling equipment can withstand surges. A good practice is to size the equipment to the capacity of conveying equipment, even if the actual requirement is substantially less. Equipment should be equipped with motion sensors.
Operation and maintenance
With a properly designed dust collector, good operational practices can result in a reduction of downtime, emissions and hazardous conditions. The following practices are recommended:
Contributed by the Filtration Team.
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For those who dream of engineering missions on alien planets, there is no better teacher than experience. Parker Aerospace may not engineer robots to load alien planet samples on rockets and cargo spacecraft for another century. However, this past year Parker was involved in exactly this challenge with FIRST and their annual FIRST Robotics Competition Regional, a science, technology, engineering, and mathematics (STEM) challenge for students around the world.
While the theme for the challenge rotates, this year the competition was organized around a space exploration concept. Parker is one of many sponsor organizations that include Boeing, Collins Aerospace, 3M, LEGO, NASA, Lockheed Martin, Motorola, Disney, and many others who made this season of FIRST Robotics possible.
Inspiring youth with STEM education
Founded in 1989, For Inspiration and Recognition of Science and Technology (FIRST) was created to inspire young people’s interest and participation in science and technology. This nonprofit organization designs innovative programs that build self-confidence, knowledge, and life skills while motivating young people to pursue education and career opportunities in science, technology, engineering, and math. Also working in a competitive environment, FIRST makes a point to teach Gracious Professionalism™ as its ethos for interpersonal conduct.
FIRST offers different programs to target many age groups:
The organization has more than 530,000 students, 60,000 teams, and 80 countries that participate annually.
For 2019 the theme was space exploration with “FIRST Launch” with the details of enabling vehicles that work on another. This includes a very detailed set of rules that define parameters for the game, arena, robots, humans, safety, conduct, construction, and more.
For the high school students participating in the FIRST Robotics Competition (FRC), the competition was named Destination: Deep Space. In this scenario, two competing alliances collect samples on an alien planet. With only 2:30 minutes until liftoff, the alliances must gather as many cargo pods as possible and prepare their spaceships.
This competition uses robots to load a hatch panel at a loading station depot. Six cargo items (orange balls) can be loaded in each of the depots after the hatch panel is installed. Each team may pre-load one hatch panel and a cargo ball, otherwise, these must be retrieved from stations and assembled or collected.
At the beginning of each game, an imaginary sandstorm limits driver visibility, so robots independently follow pre-programmed instructions or are operated by human drivers via video feedback from their driver stations. Alliances can score points during this period by:
At T-minus 2:15 the sandstorm clears, and human operators take control of their robots with full visibility. The alliances continue to score points by:
To make the competition more challenging, the habitat includes an elevated platform that the robot can climb onto at the end of the match. Various bonus points can be scored while penalty points can also be incurred. At T-minus 0 the rockets liftoff and the round ends. The alliance with the highest score at the end of the match wins.
As a sponsor organization, Parker Aerospace was matched with one of the teams, Troy Robotics from Troy High School in Fullerton, California. Parker is a financial sponsor of the team for FIRST Robotics Competition, and also partners with the Troy school to provide a summer internship program for students.
For the last nine years, Troy students have participated over the course of weeks on a range of hands-on engineering projects with Parker Aerospace’s Control Systems Division and, this year, with Parker’s Customer Support Operations. Students have worked on circuit design, coding projects, fixture overhaul, database management, documentation, and software evaluation.
For the FIRST Robotics Competition Regional held at the Orange County Fair & Event Center, 15 employees volunteered this year from within Parker Aerospace for roles such as robot inspector, judge, or scorekeeper. As experienced professionals donating their time for a good cause, they shared their insight as they interacted with students.
Parker Aerospace wishes to give special recognition to team member Jenny Chung for helping to lead Parker’s efforts with FIRST. She first participated in the program as a student and is passionate about the organization because she’s experienced its benefits. For the last 13 years, she has volunteered with FIRST as an emcee, Judge Advisor (leading the judging team), a member of the FIRST Robotics Competition Orange County Regional Planning Committee, plus was a translator for international teams from China competing at the World Championship event.
Additionally, she has served as a mentor to elementary school FIRST Lego League teams and high school FIRST Robotics Competition teams. For her involvement and dedication, Jenny was named the 2019 Outstanding Volunteer of the Year by FIRST for her work in Orange County, California.
Women in STEM panel
Going a step further to share their insight with students, two Parker Aerospace employees participated in a panel discussion about women in STEM. Meghan Boyd is a value stream manager overseeing military flight control actuation and has been with Parker Aerospace for 12 years. Vivien Fang is an engineer managing aftermarket components and has worked with Parker Aerospace for five years.
A total of seven women came together to share their insight and advice from decades of working in aerospace, engineering, and manufacturing for the benefit of the students who are thinking about their future careers. Each panelist talked about her experiences, gave guidance, and took questions from the audience.
Parker Aerospace volunteers
Pictured: Jeremy DeTevis, Tasneem Bhaijee, Anna Alcala, Riza Dayapera, Mohamad “Mo” Dagher, Cynthia Mescher, Josh Bugni, Jeffrey Hsu, Austin Weems, Jenny Chung, Kevin Le, and Reza Jamasebi
This post was contributed by Brian King, eBusiness manager, Parker Aerospace
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For those who dream of engineering missions on alien planets, there is no better teacher than experience. Parker Aerospace may not engineer robots to load alien planet samples on rockets and cargo spacecraft for another century. However, this past year Parker was involved in exactly this challenge with FIRST and their annual FIRST Robotics Competition Regional, a science, technology, engineering, and mathematics (STEM) challenge for students around the world.
While the theme for the challenge rotates, this year the competition was organized around a space exploration concept. Parker is one of many sponsor organizations that include Boeing, Collins Aerospace, 3M, LEGO, NASA, Lockheed Martin, Motorola, Disney, and many others who made this season of FIRST Robotics possible.
Inspiring youth with STEM education
Founded in 1989, For Inspiration and Recognition of Science and Technology (FIRST) was created to inspire young people’s interest and participation in science and technology. This nonprofit organization designs innovative programs that build self-confidence, knowledge, and life skills while motivating young people to pursue education and career opportunities in science, technology, engineering, and math. Also working in a competitive environment, FIRST makes a point to teach Gracious Professionalism™ as its ethos for interpersonal conduct.
FIRST offers different programs to target many age groups:
The organization has more than 530,000 students, 60,000 teams, and 80 countries that participate annually.
For 2019 the theme was space exploration with “FIRST Launch” with the details of enabling vehicles that work on another. This includes a very detailed set of rules that define parameters for the game, arena, robots, humans, safety, conduct, construction, and more.
For the high school students participating in the FIRST Robotics Competition (FRC), the competition was named Destination: Deep Space. In this scenario, two competing alliances collect samples on an alien planet. With only 2:30 minutes until liftoff, the alliances must gather as many cargo pods as possible and prepare their spaceships.
This competition uses robots to load a hatch panel at a loading station depot. Six cargo items (orange balls) can be loaded in each of the depots after the hatch panel is installed. Each team may pre-load one hatch panel and a cargo ball, otherwise, these must be retrieved from stations and assembled or collected.
At the beginning of each game, an imaginary sandstorm limits driver visibility, so robots independently follow pre-programmed instructions or are operated by human drivers via video feedback from their driver stations. Alliances can score points during this period by:
At T-minus 2:15 the sandstorm clears, and human operators take control of their robots with full visibility. The alliances continue to score points by:
To make the competition more challenging, the habitat includes an elevated platform that the robot can climb onto at the end of the match. Various bonus points can be scored while penalty points can also be incurred. At T-minus 0 the rockets liftoff and the round ends. The alliance with the highest score at the end of the match wins.
As a sponsor organization, Parker Aerospace was matched with one of the teams, Troy Robotics from Troy High School in Fullerton, California. Parker is a financial sponsor of the team for FIRST Robotics Competition, and also partners with the Troy school to provide a summer internship program for students.
For the last nine years, Troy students have participated over the course of weeks on a range of hands-on engineering projects with Parker Aerospace’s Control Systems Division and, this year, with Parker’s Customer Support Operations. Students have worked on circuit design, coding projects, fixture overhaul, database management, documentation, and software evaluation.
For the FIRST Robotics Competition Regional held at the Orange County Fair & Event Center, 15 employees volunteered this year from within Parker Aerospace for roles such as robot inspector, judge, or scorekeeper. As experienced professionals donating their time for a good cause, they shared their insight as they interacted with students.
Parker Aerospace wishes to give special recognition to team member Jenny Chung for helping to lead Parker’s efforts with FIRST. She first participated in the program as a student and is passionate about the organization because she’s experienced its benefits. For the last 13 years, she has volunteered with FIRST as an emcee, Judge Advisor (leading the judging team), a member of the FIRST Robotics Competition Orange County Regional Planning Committee, plus was a translator for international teams from China competing at the World Championship event.
Additionally, she has served as a mentor to elementary school FIRST Lego League teams and high school FIRST Robotics Competition teams. For her involvement and dedication, Jenny was named the 2019 Outstanding Volunteer of the Year by FIRST for her work in Orange County, California.
Women in STEM panel
Going a step further to share their insight with students, two Parker Aerospace employees participated in a panel discussion about women in STEM. Meghan Boyd is a value stream manager overseeing military flight control actuation and has been with Parker Aerospace for 12 years. Vivien Fang is an engineer managing aftermarket components and has worked with Parker Aerospace for five years.
A total of seven women came together to share their insight and advice from decades of working in aerospace, engineering, and manufacturing for the benefit of the students who are thinking about their future careers. Each panelist talked about her experiences, gave guidance, and took questions from the audience.
Parker Aerospace volunteers
Pictured: Jeremy DeTevis, Tasneem Bhaijee, Anna Alcala, Riza Dayapera, Mohamad “Mo” Dagher, Cynthia Mescher, Josh Bugni, Jeffrey Hsu, Austin Weems, Jenny Chung, Kevin Le, and Reza Jamasebi
This post was contributed by Brian King, eBusiness manager, Parker Aerospace
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I had a brief career in construction. We used an old hydraulic manlift for elevated projects, and it had a problem – we would start the day eye-level with our work, and after an hour would realize we were balancing on our toes to reach the same level. Cylinder drift was to blame. The lift cylinder was slowly retracting while the machine was off. In a manlift, it’s an annoyance requiring you to raise yourself every half hour, but the drift is dangerous if lifts are used to support heavy loads with the possibility that people or equipment may be under them. This is one reason why when doing automotive repairs and working underneath a car, you should always use solid jack stands or blocks instead of the hydraulic jack.
Hydraulic anatomy
A guy on my crew told me the lift slowly sank because the piston seals needed to be replaced. I wasn’t a seal engineer at the time, so it sounded reasonable. Now I know drift is more complicated, and it’s critical to understand if you’re responsible for cylinder design. Hydraulic cylinders have two main components: the piston, which is acted upon by pressurized fluid to create force and motion, and the rod, which transfers force and motion to the machinery (in my case, the lift platform) (Fig. 1). Located elsewhere are valves that open and close, controlling fluid flow into the cylinder.
Figure 1. Typical hydraulic cylinder
How drift worksLet’s remove the piston completely. We now have just a rod in a bore, which is known as a ram-style cylinder (Fig. 2). Assume we have perfect, leak-free valves and rod seals. If we shut both valves, zero oil can enter or leave the cylinder.
Figure 2. Piston removed -- ram style cylinder
Since moving the rod changes the fluid volume inside the cylinder (the rod takes up space), fluid MUST flow into or out of the cylinder for it to move.
Since this can’t happen while our perfect valves are closed, the rod can’t move. This is called hydraulic lock.
As you can see with hydraulic lock, bad piston seals wouldn’t cause drift in our manlift. Volume loss or escape from the cylinder is what caused us to slowly droop back to the floor. In my situation, either the valves were leaking, slowly reducing the volume of oil in the cylinder, or leaky rod seals (easier to spot) were allowing the fluid to escape the system.
There are a few caveats to this scenario. We assume oil is incompressible, which is not entirely true. Because the oil does squish and stretch a little, the rod will move a small amount with large load changes (read up on ‘bulk modulus of hydraulic oil’). This is not drift, since the oil quickly reaches equilibrium and the rod will not continue to move.
Single-acting cylinders (Fig. 3) are an exception, because oil leaking across the piston is leaving the system. This is similar to when the rod seals leak in double-acting cylinders – drift occurs. Double-ended cylinders (Fig. 4) are also an exception because the fluid volume in the cylinder does not change as the rods move. Both of these systems require low leak piston seals to prevent drift.
Figure 3. Single-acting piston
Figure 4. Double-ended cylinder
Why leaky piston seals are a problem
Leakage across the piston doesn’t cause drift but can cause a number of other complications. Rod retraction relies entirely on the piston seal blocking pressure from crossing the piston; I’ve already described how simply pumping fluid into one side of a cylinder without a piston seal will only cause the rod to extend. Using fluid pressure to retract the rod is not possible without a piston seal.
When extending the rod or holding a load (valves open, no hydraulic lock applied), leakage across the piston seal slowly allows pressure to equalize on both sides of the cylinder. Once this happens, effective piston diameter drops to only the diameter of the rod (Fig. 5). Pushing or supporting the same load now requires higher fluid pressure. This can raise pressures higher than the system was designed to see, cracking pressure relief valves.
Figure 5. Reduction in effective piston diameter
In summary, a leaky piston seal won’t cause drift, but it’s bad for efficiency and could damage the system.
Picking the right piston seal
In systems that are quickly cycling, a slow piston leak may go unnoticed as a tiny efficiency loss – the pressure reverses before a significant amount of fluid can leak past the seal to cause problems. On the other hand, cylinders that move slowly or must hold a position for extended periods benefit from no-leak piston seals.
At Parker, we see a wide variety of applications, and we manufacturer piston seals in many styles and materials to cover all of them. Softer durometer materials like those used for our PSP and T-seals are better for tight sealing. Harder durometer materials like our BP and PTFE cap seals are more extrusion resistant and wear longer in fast-stroking applications.
We also offer hybrid designs like our CQ profile. The CQ design utilizes glass-filled PTFE for low friction and long-wearing but also features a rubber insert to reduce leakage.
Conclusion
Cylinder drift is a concern in many hydraulic applications. It’s commonly mistaken as piston seal failure but is usually a combination of factors involving the valves. Understanding cylinder mechanics is vital to identifying the root causes of failure and for designing systems that are resistant to drifting.
Recommendations on application design and material selection are based on available technical data. They are offered as suggestions only. Each user should make his own tests to determine the suitability for his own particular use. Parker offers no express or implied warranties concerning the form, fit, or function of a product in any application.
This article was contributed by Nathan Wells, application engineer, Engineered Polymer Systems Division.
Optimum Sealing Performance, Even in Low-Pressure Conditions With the HL Rod Seal
Gone are the days where equipment must be serviced on a set schedule. IoT technology helps enable maintenance based on equipment use. For instance, in an IoT solution for heavy equipment, cloud-based machine analytic sensors detect depleted parts and hardware before failure that extends the lifecycle of the components. Equipment health status monitoring ensures that over-used equipment components receive maintenance sooner than later, while lightly used products aren’t serviced unnecessarily.
It has also been revealed that more than one-third of the maintenance spend is wasted in ineffective or unnecessary upkeep. But what if there was a way to reduce unnecessary maintenance costs? What if there was a way to not only stop spending money on unnecessary maintenance and prevent paying the steep prices from emergency breakdowns, is it something you would consider?
It is important to distinguish between predicative and preventative maintenance. Unlike preventative maintenance, which seeks to decrease the likelihood of an equipment failure through the performance of regular maintenance, predictive maintenance relies on data to determine a machine’s likelihood of failure before that failure occurs. This allows heavy equipment manufacturers and fleet managers to move from a repair and replace model to a predict and fix maintenance model using predictive analysis — which relies on data, statistics, machine learning, artificial intelligence and modeling to make predictions about future outcomes.
Manufacturers and service technicians are now utilizing smart sensors to improve the maintenance process and avoid inefficient routines and the costs that go along with them. Essentially, the preventative maintenance technology allows heavy equipment OEMs and fleet managers to analyze the operational data from each piece of equipment to identify any patterns that emerge to predict when maintenance will be required. All in all, proactively maintaining off-road equipment as opposed to unnecessary time-based maintenance or relying on reactive maintenance can create real economic value by lowering overall operating costs and prevent major headaches for the OEMs and fleet managers.
Proactive maintenance with an IoT solution specifically designed for heavy off-road equipment can not only drastically reduce the amount of time and money spent on maintaining equipment, but also extend the longevity of the equipment.
Thanks to a combination of IoT and machine learning, technicians are not only able to remotely check the condition of in-service equipment, the equipment provides guidance as to when maintenance should be performed. This approach promises cost savings over routine or time-based preventive maintenance because tasks are performed only when necessary.
Off-road equipment with IoT technology, such as Parker’s Mobile IoT, has the ability to send detailed information to the maintenance department without having to send a technician to a job site. If onsite maintenance is required, the data provided will ensure that the technician has the right tools and parts on the first trip, which can reduce downtime, labor and travel costs.
Predictive and remote monitoring maintenance are just two examples of how IoT is a game changer in the mobile equipment industry. The opportunities that we have to positively improve maintenance costs on heavy or off-road equipment is too valuable to leave unexplored. Don’t wait for another breakdown to happen. Be proactive and prevent catastrophes and unnecessary costs by monitoring the equipment and stopping the problems before they happen and schedule a Parker Mobile IoT demo today.
Article contributed by Clint Quanstrom, IoT general manager, and Kyri McDonough, marketing communications manager, Parker Hannifin Corporation.
Other related topics on Parker Mobile IoT solution:
The ROI of IOT for OEMs
The Strategic Approach to Fleet Optimization for Heavy Equipment
Connecting the Dots Between IoT Data and Equipment Efficiency for OEMs
Delivering Visibility and Reducing Fleet Management Costs
In today’s world where time is precious, doing the job right the first time is critical. Your customers want reliability and appreciate the attention to detail that will ensure their system provides cooling or heating when they want it. So how does one minimize the callbacks and warranty servicing on the units they installed or serviced? Using the best contamination control practices is a good starting point.
All HVACR technicians learn the basics when they go through technical school but many of us may have forgotten a few of the not so obvious steps. So, a quick refresher may help you improve the quality of your installations, increase your customer satisfaction and referrals that drive repeat business, growth, and the bottom line.
Good contamination control starts with the installKeep out debris. There are many opportunities for dirt, solder, flux, copper chips, etc. to be introduced during the installation of the air-conditioning or refrigerating unit. Minimizing the introduction of solid materials is easy by covering the open connections to the system and ensuring tubing and components are free of chips, burrs, caps, etc.
Use flushing products correctly. Flush products can be used to clean the tubing and/or coils being reused to remove residual oil, wear particles, burnout residue, etc. Too often a technician will inject the cleaner and then let gravity drain the fluid to the collection device. Most flush systems recommend using pressurized air or nitrogen to blow out all of the liquid. If this step is not completed, much of the flush will remain in the tubing and will eventually evaporate but will leave behind all of the debris that would have been ejected.
Install a high performance filter-drier. Many of today’s air-conditioning and heat pump comfort conditioning systems come with a filter-drier, some even come installed. Installing the provided unit only costs a few seconds of braze time and some alloy and gas but will provide the unit with all of the reliability which the system design engineer intended and validated. If the unit did not come with a filter-drier, then installing a properly sized high quality, time proven Catch-All® can ensure contaminants like water, acids, sludges and varnishes are captured before they can react with system materials. These materials may react with compressor windings leading to compressor burnout or cause copper plating which reduces bearing clearances or poor valve seating eventually causing failure. Or they can deposit in the expansion device restricting flow or proper modulation of thermostatic or electric expansion valves. Loss of superheat control can lead to lack of cooling if the evaporator is starved or even worse, flooding of liquid back to the compressor causing bearing washout and eventual compressor failure.
Install a See-All® Liquid and Moisture Indicating Sightglass. This is the only device that can provide a real-time look at the worst system contaminant of them all, water. It also indicates if subcooling is present when it is solidly full of liquid or if it has been lost when vapor bubbles are seen. For negligible cost, it enables the technician to quickly see if the refrigerant has excessive water in it, if the filter-drier needs changing, and a quick check of system charge with just a glance.
Eliminate brazing scale. During brazing, the hot copper can react with oxygen from the air to form copper oxide. This black flakey scale readily detaches from the tubing wall and is pushed around by the refrigerant clogging fine ports and passages in valves, compressors, etc. wreaking havoc on their functionality. Purging the line with nitrogen stops this reaction and should be everyday practice. Alternately, ZoomLock® flame-free refrigerant fittings introduce no heat and will accomplish this goal even easier and faster.
Evacuate the system prior to charging. Pulling a strong vacuum, 500 microns or per manufacturer's instructions, to remove the air has never been easier. Today’s dual stage vacuum pumps are easily capable of achieving this level of vacuum. This eliminates the air that wants to react as well as ensuring full condenser capacity and reduces compressor work. It will also pull water from the tubing surfaces and other components in the system leaving less highly reactive materials in the closed system.
Charge the system properly. A properly charged system will provide the required cooling or heating with the least energy usage and system runtime. Conversely, a low charge will provide less compressor cooling along with poor system capacity/efficiency. Overheating the compressor eventually leads to compressor failure, carbon debris, and sludge-like material formation that will adversely affect the replacement compressor.
Clean-up large systems quickly and completely. Large multiple compressor and multiple evaporator systems are much more difficult to assemble without introducing significant solid debris, moisture, and air. Changing the cores in the liquid line shell and using a secondary filter will capture moisture and solid trash quickly and effectively, even down to very small particles. The clean-up is complete when the See-All indicates the system is dry and the cores/filter-elements have been replaced so they can continue to capture generated debris.
Follow these steps to ensure reliability
Following these simple steps eliminates many of the reliability-robbing contaminants and provides the ability to monitor and remove any contaminants that made it into the system. In addition, the Catch-All will continue to capture solid debris, sludges, moisture, and acids protecting the TEV and compressor. However, routine maintenance of systems can significantly improve their reliability and should not be neglected.
For more information on sizing filter-driers and system clean-up procedures please see Parker Sporlan Bulletin 40-10. For various HVAC and Refrigeration product information visit www.Parker.com/Sporlan.
Article contributed by Glen Steinkoenig, product manager, Contaminant Controls, Sporlan Division of Parker Hannifin.
Additional resources for you:
HVACR Tech Tip: How to Apply Filter-Driers on Heat Pumps for System Protection
Use of Suction Line Filter-Driers for HVAC Clean-up After Burnout
HVACR Tech Tip: When Should a Catch-All Filter-Drier be Changed?
You just spent 6 months testing, stretching, aging and exposing your new seal design to 12 different chemicals. Finally, you are done, so what does a good technical drawing for a seal include? For most companies, the drawing is simple. For an O-ring, we draw a generic circle and show an ID and width with some sort of material call out. But now fast forward 20 years, someone consults the drawing, how do they know the criteria you used to select the seal specified?
Just last week I asked my customer who was having seal failure issues on their engine sensor, “Was the original seal specified to be compatible with biodiesel?” The engineer consulted their drawing, but besides the generic circle it lacked any background on what material compatibility was considered when the seal material was selected. The ASTM description on the drawing did not include a reference to or indicate compatibility with biodiesel.
Be specific with materialsOver time, the operating parameters of a system or product can change so it is important to know what parameters were used for the original seal selection. The goal of the drawing is to assure that the engineers and procurement team understand what performance is required from the seal and why the specific elastomer was chosen.
So how do you make your drawing more valuable to your company?
Define and list on your drawing all the operating conditions you anticipate the seal will see such as temperature, pressure and any other application specific operating conditions.
Prepare a list of fluids as well as the concentrations of each fluid that your seal will be exposed to and again add these on your drawing. In addition, make sure you consider fluids that could come into contact with the seal indirectly, through failure of other systems that are part of the product or even by cleaning the product.
List on the drawing the selected compound and manufacturer. Define clearly what testing the compound was put through or what testing is required for approval.
If you select a compound that was resistant to compression set, high temperatures or low temperatures as well as explosive decompression, this should be clearly stated on the drawing.
List clearly the industry standards the seal is required to meet, such as UL, FDA or NSF.
List fluid compatibility requirements
Time and time again, I see seal quality and performance failures when a new supplier is selected and the real requirements for the seal were either forgotten or not clearly defined. Clearly defining these parameters and making them transparent will allow your purchasing and technical team to understand, select and evaluate the correct compound that meets your products sealing requirements.
Once you select a compound for your specific application, it is important to test and validate that the compound chosen is compatible with the fluids you are using. Parker can typically supply small compound samples for soak testing in the fluids your seal is exposed to. If you choose to list an alternate compound on your drawing, that compound must also be tested and validated for compatibility.
Parker offers design assistance for all of our sealing products so before you even design the seal, define the space or groove the seal fits into. Call us, the earlier in the design process the better. Parker will assist you with selecting the proper seal, defining the elastomer requirements, and designing the mating groove; we can provide a cost-effective solution whether it is off the shelf or a custom manufactured solution
Remember when developing drawings standards, assure yourself that if someone consults a drawing that is 2 years old, 5 years old or even 20 years old, they will know what the original seal design intent was.
Fred Fisher, technical sales engineer, Parker Hannifin Engineered Materials Group
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As a global industrial leader, Parker’s manufacturing operations can have a significant and widespread impact on the world, and the company recognizes the importance of acting responsibly with the planet’s natural resources.
Parker’s 2018 Sustainability Report features examples selected from hundreds of submissions that demonstrate initiatives driven by Parker team members, aimed at improving their local communities and helping to protect the environment.
Energy management
At Parker manufacturing facilities around the world, team members continue to research and implement creative solutions to reduce energy consumption and emissions by optimizing manufacturing processes and modernizing equipment. Given the scope of Parker’s manufacturing operations, increasing energy efficiency represents a significant opportunity to reduce environmental impact. Since 2004, Parker has reduced its energy use index, which measures energy consumed per unit of sales, by more than 50%. This included a 1.6% reduction in absolute energy consumption and a 2.3% reduction in carbon emissions in calendar year 2017.
Since 2008, Parker has reported its energy and emissions data to the Carbon Disclosure Project (CDP). In 2018, Parker’s Climate Change Score ranked in the top quartile among its diversified industrial peer companies.
Company car policy
Parker Sweden
The transition from traditional gasoline and diesel to vehicles powered by renewable energy represents a significant opportunity to reduce emissions and protect the environment, and Parker Sweden is helping to lead the charge. A new country-wide company car policy encourages team members to choose hybrid or electric vehicles for business use. With a fleet of 125 company cars and an average annual mileage of approximately 18,640 miles (30,000 kilometers), Parker Sweden estimates the new policy is reducing fuel consumption by 18,492 gallons (70,000 liters), helping to reduce emissions by up to 25% without increasing cost.
Waste recycling down under
Parker Australia - Castle Hill, Australia
In evaluating opportunities to reduce their environmental footprint, the division’s Supply Chain: Procurement & Warehouse High Performance Team noticed that paper, cardboard and wooden pallet waste was being discarded with regular trash, a realization that gave way to a major recycling project with significant results. By creating processes that enabled the proper disposal of key materials without creating extra work, installing colored and clearly labeled bins and partnering with two local companies that offered no-charge recycling, the plant has increased the amount of paper and cardboard recycled from 9% to 50% in the first year, and reduced waste management costs by nearly $90,000. The team plans to build on its success by adding glass and plastic recycling and supporting the rollout of this initiative at other Parker sites across Australia.
Weathering the storm
Pump & Motor Division Europe - Vierzon, France
After experiencing two significant storms that brought heavy rain and flooding throughout the region, the division became aware that their existing infrastructure was not fully capable of capturing and diverting large volumes of rainwater, which created a number of potential risks related to safety and production downtime. The facilities team not only installed an updated high capacity drainage system that reduced water recycling costs by nearly $25,000, but used it to redirect falling rain to a new self-contained lagoon outside the facility, complete with natural reed beds to help purify the water.
Commitment to recycling
All locations
Parker team members are taking action to conserve resources and help protect the environment. Today Parker recycles more than 85% of the waste generated from its manufacturing operations, and the company continues to make progress toward its goal of reducing water use and the volume of waste sent to landfills by 20% between 2015 and 2020. This year Parker also engaged in several strategic partnerships that will help support environmental initiatives, including the implementation of a fluid management program and ongoing development of a resource tracking and reporting structure.
Download the 2018 sustainability report to learn more.
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Parker’s 2018 Sustainability Report Highlights Commitment to Social Responsibility
Sustainability Report Highlights Team Members’ Efforts to Improve Their Workplaces and Communities
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