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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)
What does the gear ratio mean to me?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.
210 Series PTO & 524 Series Rear Mount 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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Parts 1 and 2 of this series discussed the theory behind CSR testing and what to look for in a CSR result curve. This 3rd and final section will focus on how to use CSR data and apply it to real world applications and how to incorporate it into a material specification.
For the reasons discussed previously, it is important to view a full CSR curve, rather than a single data point, and to resist the urge to draw conclusions from incomplete data. For example, Figure 1 compares a FKM to an HNBR material. Because the fluorocarbon material has a larger viscoelastic loss within the first 24 hours of the test, it appears to be worse (less retained seal load) than the HNBR for most of the test duration. However, the slope of the HNBR curve is steeper than that of the fluorocarbon, and the curves of retained load force cross at about the 2,300 hour point. If these curves are extrapolated, the HNBR is predicted to reach the point of zero residual load force at 4,262 hours, whereas the fluorocarbon is not expected to reach the same point until 8,996 hours have elapsed. Had the HNBR material been selected for this application based solely on the higher percent retained load force observed at 1,008 hours, the end user would have achieved roughly half of the service life they could have enjoyed had they selected the FKM compound instead.
Figure 1: An HNBR and a fluorocarbon in engine oil.
4 Limitations of CSR dataSeveral caveats remain in attempting to use CSR curve data to predict real-world performance. First, a CSR procedure cannot mimic real-world application conditions. In fact, it is not intended to. CSR testing is meant to be an accelerated aging test, where specimens are exposed to constant temperatures hotter than anticipated in the actual application. While some continuous CSR test machines are capable of temperature cycling, no CSR test can realistically replicate the actual temperature conditions, pressure fluctuations, or vibration seen in a real-world application. Second, CSR testing cannot replicate actual fluid exposure conditions seen in typical seal applications. CSR testing completely immerses a rubber specimen in a small amount of fluid that is kept at a high temperature – typically hot enough and with enough air exposure to cause the fluid to degrade. In a real-world application, a seal is usually installed in a groove with fluid exposure on one side and air on the other. In many applications, the fluid is contained within a sealed system that minimizes oxidative degradation of the fluid. Third, there is as yet no definitive correlation between the onset of leakage and residual load force, regardless of whether that force is expressed in absolute terms (Newtons or pounds-force, for example) or as a percentage of the initial developed load force. Finally, because low temperatures are more challenging for a seal, cycling the temperature to include load force measurements at -40°C would be considered a worst-case scenario. Continuous measurement CSR devices are now commercially available with the capacity for running such a temperature cycle, but their use to date has been extremely limited due to the cost of the equipment.
Other considerationsSeveral factors should be considered before incorporating CSR testing into a material specification. CSR is a more expensive procedure than compression set, and it requires dedicated and expensive test equipment. As a result, it is not always appropriate to replace compression set testing in a material specification with CSR testing. Second, establishing limits for “what good looks like” should never be done arbitrarily. It is extremely difficult to convert a real world application service life into a number of test hours at a set temperature. Therefore, it is more practical to start with a material that is known to maintain a satisfactory service life in the application, test it for CSR at a relevant temperature, and establish meaningful limits based on the performance of that material. Finally, resist the temptation to get too exotic with specification limits. For example, it may seem valuable to impose specification limits related to the slope of the CSR curve or to the extrapolated “time to zero load force”. These can be valuable tools for gathering engineering insight, but they are far too complicated to incorporate as specification limits. CSR is a more complicated test than compression set, and it requires more “homework” to set proper limits and test conditions.
In conclusion, Compressive Stress Relaxation is a powerful tool for comparing the performance of two or more materials in a particular application, provided it is done on an apples-to-apples basis. It also serves as a reasonable means of (roughly) estimating the long-term service life of a seal material in a given application. There are too many assumptions for it to be used to guarantee a specific level of performance, and there remains much work to be done in correlating results to real-world observations, but it currently offers the best laboratory-scale means of evaluating a seal material for long-term use in a given application.
This article was contributed by Dan Ewing, senior chemical engineer, Parker Hannifin O-Ring & Engineered Seals Division.
How Much Do You Know About Compressive Stress Relaxation? CSR Part 1
How Much Do You Know About Compressive Stress Relaxation? CSR Part 2
How to Read a Rubber Test Report: The 4 Most Common Misunderstandings
Reduce Downtime and Costly Seal Replacements: Seal Failure Diagnosis Part 1
Quick connections for high-pressure, hydraulic applications have evolved immensely over time to satisfy new processes and operational needs. As industries advance their capabilities, the demand grows for coupler capabilities. Today, couplers must ensure fluid handling applications meet both safety and regulatory standards while simultaneously provide optimized containment of a wide range of fluids that can have different operational conditions.
Operators have continually depended on reliable connections for a “non-spill” experience under the most extreme conditions, such as temperature or high pressure. Manufacturers saw this as an opportunity to introduce new and enhanced couplers to the market.
Flush face valving delivers near-zero spillageCouplings, specifically non-spill, are engineered to combat hydraulic leaks and spills with a unified design incorporating sophisticated components. For reference, the term “non-spill” regarding a coupling means a specific type of connector can reduce fluid spillage to near zero whenever a coupling is connected and disconnected. Designed initially as heavy-duty metal couplings for high-pressure, industrial applications, non-spill couplings have evolved into a variety of materials to complement a wide range of applications requiring minimal spillage and air inclusion.
The flush face design became a significant advancement in quick coupling architecture. A “no-drip” valve means no more than a coating of liquid will appear on the valves’ surface, establishing repeated dripless connections and disconnections for a cleaner, safer work environment. Also, inclusion, which represents the air put into the fluid system during each connection, is drastically reduced through a flush face valve. The benefits of near-zero spillage and air inclusion have become critical in many applications, from heavy-duty construction equipment to hydraulic hand tools and general industrial machinery.
Parker’s non-spill quick couplingsParker is the global leader in quick couplings, delivering a spill-free and lasting performance, with a wide range of non-spill coupling solutions to fit versatile fluid applications. The FEM Series, FET Series and 59 Series all provide minimal fluid loss and air inclusion, as well as chemical compatibility when necessary.
FEM seriesThis non-spill quick coupling satisfies the design and performance requirements set forth by the ISO 16028 International Standards for quick coupling interchangeability. Featuring a push-to-connect design, FEM Series delivers an extra level of security for simple connections without causing any joining, crimping or soldering materials, eliminating spillage and air inclusion during connecting and disconnecting.
In addition, Parker provides an optional FEC male nipple, which allows connect-under-pressure capabilities with the FEM female coupler. This option is designed for applications where residual pressure makes connection difficult.
FET seriesThe FET Series non-spill quick coupling, engineered for reliable performance with equipment experiencing powerful impulses, accommodates the most demanding hydraulic applications. Parker’s FET Series couplings connect under pressure at 6,000 psi and disconnect up to 2,500 psi in environments that desire the security of a threaded connection under residual pressure. These couplers are built to operate under high-impulse mobile circuits, including excavators, and oil and gas equipment, such as umbilical lines and mobile drill rigs. Constructed of high-grade materials and a stainless steel valve, the FET Series features a robust Brinell resistant design and plating for extended durability and corrosion resistance.
59 seriesIdeal for use in high impulse applications with multiple high-pressure hydraulic lines, the 59 Series ensures consistent connections and disconnections under residual pressure. A powerful ACME thread utilizes a double start feature and allows a full connection to be completed in 2 – ½ turns, saving time and eliminating frustration. Its size and shape of the heavy-duty ACME thread make the coupling resistant to damage, easier to clean and ready for operational use.
An internal bearing between the collar and body eases resistance and minimizes the challenge of handling pressurized lines. In addition, the coupler and nipple have non-spill stainless steel valves and can be connected under pressure up to 5,000 psi and disconnected under a pressure of 2,500 psi.
Review our non-spill product pages for your specific applications. Or contact one of our product experts for more information or a price quote.
Contributed by Lori Aus, product sales manager, Quick Coupling Division, Parker Hannifin.
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Electrically conductive elastomers are elastomeric polymers filled with metal particles. They can be grouped by filler type and elastomer type. Then within each of these classes, there are standard materials and specialty materials.
Parker Chomerics manufacturers electrically conductive elastomer gaskets, also known as EMI elastomer gaskets, under the CHO-SEAL brand. We won't get so much into gasket configurations and dimensions here, we'll just stick to classes of materials. So what is available? Let’s find out.
Conductive elastomers are metallic particle filled elastomeric polymers, the particles giving the shielding performance and the polymer making them “rubber." There are many materials within this generic material type, but we'll focus on the below.
Setting up the grades of conductive elastomers by filler types involves six different particles:
Three types of elastomer material
All of these materials are cured or cross linked when the gasket is made. The cure either happens with heat or atmospheric moisture.
In general, for small cross sectional electrically conductive elastomer shapes, the smaller the particle the more producible the part will be. Particle fillers have little to do with mechanical properties of the gasket except that they simply increase hardness.
Now that you have more information about how to select particle and polymers for electrically conductive gaskets, download or Electrically Conductive Elastomer Handbook and get started today!
This blog contributed by Jarrod Cohen, marketing communications manager, Chomerics Divison.
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In Part 1 of this series, the theory behind Compressive Stress Relaxation (CSR) testing was discussed, as well as a brief discussion of the fixtures used to measure it. In Part 2, we will explore what to look for in a CSR result. Significant understanding of how a rubber seal material responds to a particular environment can be gleaned if one knows what to look for in a CSR curve.
The end point
The first and most basic point of understanding is the end point. Does the material continue to maintain contact pressure throughout the test, or does it fall to zero (below the detectable limit of the load cell) before the end of the test? While there is no definitive correlation from residual load force to onset of leakage, it should be intuitive that a material that completely relaxes and loses all contact force is likely to leak in application. Anecdotally, multiple customers have reported that the load force must drop to very close to zero for leakage to occur in their particular test apparatus. While this is good guidance, these anecdotal reports should not be taken as a definitive answer that applies in all circumstances.
Specifications are often written such that a minimum of 10% of the initial contact load force must remain for a passing result. In practice, there is nothing special about 10%. This is a semi-arbitrary value that ensures a material continues to apply some non-zero load force to the mating surfaces, with some safety factor to ensure that it does so even after all normal test variations are considered. In practice, this appears to be a conservative limit, there is nothing magical about the 10% number.
The loss of compressive load force can be broken down into three different types of phenomena, each with its own time frame. All rubber materials relax viscoelastically when initially compressed, and this loss stabilizes within the first 24 hours. That initial drop seldom has much direct impact on real-world applications. However, in the specific case of an assembly having neither a compression limiter nor solid-to-solid contact, meaning the assembly torque of the fasteners is controlled solely by compression of the seal, this will be observed as “torque fade” if the fastener torque is rechecked a day or two after assembly. In such a case, Parker recommends against retorquing the fasteners unless leakage is observed as this retorquing can easily result in damage to the seal from excessive compression.
Solvation effectsThe second set of phenomena to resolve are solvation effects that occur when an elastomer is immersed in a liquid test media. The rubber material will absorb some amount of test fluid, causing some swelling of the rubber and a small increase in load force. When this happens, the test fluid may extract liquid constituents from the rubber, resulting in shrinkage of the seal material and a loss of load force. These processes occur simultaneously, and both typically reach equilibrium within the first 72 hours. However, the net impact on the measured load force will only be noticeable if the volume change is significant.
DegradationThe third set of phenomena are degradative effects caused by high temperatures and chemical reactions. These reactions are ongoing and cumulative. If the test temperature remains constant, the rate of degradation will remain constant, as well. Unfortunately, there is no way to distinguish what percent of any degradation is due to thermal effects versus chemical effects from a CSR curve. Comparing a CSR output curve to one generated from testing in an inert control fluid at the same time and temperature may allow a user to isolate thermal effects from chemical ones, but it must be known that the control fluid does not also produce chemical degradation of the rubber material.
Ultimately, it is more important to consider the slope of the curve after the initial drop than the initial drop itself. The material should stabilize to a relatively flat line, and the slope of that line reflects how the material responds to thermal and chemical aging effects. A curve with very little slope (Figure 1) is extremely stable long-term, whereas as a CSR curve that shows a steeper negative slope (Figure 2) means the material is continuing to degrade due to chemical and/or thermal effects in that fluid and at that temperature. This does not mean the material is incompatible with that environment, but the continuing losses mean the end of service life point (onset of leakage) would be expected relatively soon after the end of the test.
Figure 1: A fluorocarbon in engine oil at 150°C shows very little change after the initial relaxation response.
Figure 2: An HNBR in engine oil at 150° shows ongoing degradation after the initial relaxation response.
In summary, much knowledge about how a material will respond in an application can be gleaned from Compressive Stress Relaxation testing if one knows what to look for. Watch for part 3 of this series, where we will focus on how to use the understanding gained from CSR testing and how to incorporate it into a material specification.
For more information or assistance with your application, contact our applications team at oesmailbox@parker.com or chat online by visiting Parker O-Ring & Engineered Seals Division website.
This article was contributed by Dan Ewing, senior chemical engineer, Parker Hannifin O-Ring & Engineered Seals Division.
How Much Do You Know About Compressive Stress Relaxation? CSR Part 1
How to Read a Rubber Test Report: The 4 Most Common Misunderstandings
5 Factors to Consider When Determining Compressive Load of a Seal
Reduce Downtime and Costly Seal Replacements: Seal Failure Diagnosis Part 1
Reduce Downtime and Costly Seal Replacements: Seal Failure Diagnosis Part 2
The principles and practices of lean manufacturing are widely used in industries across the globe to continuously improve processes, drive efficiencies and reduce costs.
Even in biopharmaceutical manufacturing where validation and regulatory requirements are high, lean can be used to improve processes, meaning more life-saving product can reach patients quickly.
Technology has been developed to support biopharmaceutical manufacturers, CMOs and CDMOs on their lean journey and at Parker we have worked closely with industry to develop a system that can improve operational efficiency, accuracy and safety.
Parker’s SciLog® FD System automates, standardizes and encloses final bulk filtration and dispense operations. It can support companies in addressing the eight wastes of lean: Transportation, inventory, motion, waiting, overprocessing, overproduction, defects, and safety.
As an automated, standardized and enclosed single-use system, it has many advantages over manual operations. It can increase efficiency, reduce process variation, protect the product and operator, and reduce risk.
Here is how the SciLog® FD System can help manufacturers tackle the eight wastes, and support them in implementing lean production strategies.
Transportation
As the process takes place in a single, enclosed system, the movement of products and materials is reduced. The SciLog® FD System can combine two unit operations: the sterile filtration of bulk drug product and its dispense into bottles or bags. As both of these steps can be performed on one system, transport of material is reduced. Once dispensed into bags or bottles, the drug product can be easily transported for freezing or cold storage.
Inventory
The use of the SciLog® FD System simplifies the supply chain, with the hardware and consumables, including single-use manifolds, designed together and available from a single source – Parker.
Motion
Using an automated system means that the motions associated with a manual operator – for instance operating pumps and valves – are removed from the process. All of the valves are controlled automatically, with intelligent feedback from the SciLog® single-use sensors which are part of the system.
Moving materials in a laminar air flow using aseptic technique can be challenging and has a high training requirement. Reducing the amount of movement of product through the use of a closed system reduces the risk of contaminated product. The SciLog® FD System allows recipe-driven processing, sampling and integrity testing — all taking place on the one enclosed automated system limiting unnecessary motion and associated risk.
Waiting
As the SciLog® FD System is automated, it cuts down on an operator’s waiting time in between different stages of the process. This means that staff can be utilized more efficiently. For example, a recipe can be programmed to carry out an automated filter integrity test and, while this takes place, the operator can perform other activities such as checks or paperwork completion.
Overprocessing
Time-consuming, and potentially inconstant tasks that would have been carried out manually are now automated. For instance, the SciLog® FD System generates automated batch records - an alternative to the operator having to complete forms manually (and reducing the risk of transcript error). There is also an integrated label printer with labels suited to cryogenic storage.
Overproduction
Manual fill can be inaccurate - and human error can lead to more product being transferred to a bottle than is required. Clearly this can have a significant impact on production and, given the high value of the product, can be financially damaging too. By automating the bulk fill process, costly inaccuracies can be avoided. In the SciLog® FD System, load cells located under receiving containers ensure direct measurement for high dispense accuracy.
Defects
An open process which relies on manual handling can result in contamination of a product and batch loss. Enclosing the process means that the product is protected and the risk of any contamination is greatly reduced. In addition, standardization and automation eliminate process variability and enables batch repeatability. Standardized, reliable programming ensures repeatability and control in the process.
As calibrated SciPres® single-use pressure sensors are included in the SciLog® FD System, operators can ensure that validated pressure limits are not exceeded, protecting the manifold and controlling the differential pressure over the filter.
Safety
Utilizing a fully enclosed process means the product is protected from contamination by the operator, but crucially also that the operator is protected from potentially highly potent molecules.
There are also additional advantages to using Parker’s SciLog® FD System which supports the application of lean in biopharmaceutical manufacturing. Standardization means that training is made simpler and easier, and by using a single-use system, change over times can be significantly reduced. The installation of manifolds in the system is quick and easy, again reducing labour costs and time spent on manual tasks.
To learn more about how the SciLog® FD System can help you tackle the eight wastes of lean, please visit our webpage.
This post was contributed by David Heaney, market development manager, Parker Bioscience Filtration, UK
Parker Bioscience Filtration specializes in automating and controlling 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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One the biggest challenges for original equipment manufacturers (OEMs) in automotive manufacturing is ensuring reliable operation and long-term performance of equipment. Liquid and particulate contaminants, pressure build-up, temperature fluctuations and harsh environmental conditions can have devastating effects on sensitive components resulting in costly maintenance, downtime and part failure. What is the best line of defense? Are there new technologies available that provide an effective solution? Let's explore some options.
Components that are especially vulnerable include:
Many OEMs use membrane vents. Membrane vents are designed to equalize pressure and reduce condensation while preventing ingress of liquid and other contaminants to keep automotive components and devices operating properly.
When selecting membrane vents, it is important to review the following performance testing data:
Another important factor to consider when selecting membrane vents is the reputation of the manufacturer and the quality of customer service they provide. Additional attributes to look for include:
New technology
Vents made from expanded polytetrafluoroethylene (ePTFE), such as aspire® membrane laminates, are particularly effective for automotive applications. aspire membrane vents combine high water entry pressure with high air permeability to exceed automotive manufacturing requirements. The membranes are laminated to polymer meshes to provide the physical stability required for integration into automotive components and throughout operation. Proprietary oleophobic chemistry provides the level of ingress protection necessary to ensure long-term performance of automotive equipment.
aspire® performance data
Conclusion
Choosing the best membrane vent solution for automotive applications takes careful evaluation. Considering services and support the manufacturer provides, performance data and the effectiveness of the technology are key factors to ensure reliable, long-term operation of automotive components.
Article contributed by Sarah Propp, engineering manager, Parker Performance Materials.
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Computer Numerical Control (CNC) machining is a process where computer-aided design (CAD) and computer-aided manufacturing (CAM) programs are used to control the steps and functions of machine tool centers, allowing repetitive production processes to be programmed and automated. CNC machining and milling centers, as well as CNC lathes, are precision cutting machinery commonly used in industrial manufacturing applications such as metalworking. These centers have several axes, in which tools and workpieces move. Workpiece and tool changers supplement the systems so that complex geometries can be produced on one machine tool.
Today’s high-speed processing requires the introduction of cooling lubricants. These are used to cool the cutting edges on the direct contact surface to the workpiece during the cutting procedure, to lubricate the contact surface and remove any arising chippings through “purging”. Through the rotation and energy input, the cooling lubricant forms an aerosol mist, which is extremely hazardous to health if inhaled.
Let's explore how one metalworking manufacturer solved the problem of CNC machining emulsion mist and improved air quality in its production facility.
Problem:
Mauersberger und Fritzsche is an SME with a long tradition in gear manufacturing for drive technology and in the production of high-quality structural steel cupped shears. The company has CNC machining and milling centers from renowned manufacturers, such as Monforts, Doosan, Yang and Mori Seiki, in which workpieces are cooled, purged and lubricated with water-soluble cooling lubricants (emulsions). To improve air quality and safety, the corporate management team turned to Parker Industrial Gas Filtration Generation Division to design a solution to remove the hazardous emulsion mist.
Solution:
The company’s machinery comprises approximately 10 machine tools. For this reason, the advantages and disadvantages of single-station extraction units were weighed against a central extraction system.
The advantages of a central extraction system prevailed in this project. On balance, the investment costs are lower despite higher costs for piping and assembly, while maintenance is concentrated on a central point. In addition, a summer/winter set-up as hall ventilation can be easily realized with this concept. This allows exhaust air operation in the summer and a recirculated air operation in the winter to save heating costs.
In general, it is not possible to give one blanket answer to the question about single-station extraction units or central extraction systems. This must be decided on the facts of the relevant plant. However, as a general rule, the overall or life cycle costs of a central system with a ventilation system performance from 6,000m³/h tend to be lower. In this case, Parker recommended a SmogHog ESP two-staged electrostatic filter which reliably filters out harmful substances and emulsion mist, such as aerosols, and offers the client an approximately 15% reserve for production expansions.
The client was initially skeptical about an electrostatic filter solution. However, thousands of installed SmogHog electrostatic filter systems have proven successful for decades. Even oil and emulsion mists can be filtered with outstanding results if you have 50 years of knowledge like Parker. Knowledge, which can also be seen, for example, in the piping used for raw (polluted) gas, as this should be made of longitudinally welded steel and be oil-tight on the flange connections. “Cheaper” folded spiral-seam pipes are reputed to save costs but, according to Parker's experience, they carry a risk of a production hall becoming a “stalactite cave”. By visiting a comparable reference system near the client’s company, Parker was able to convincingly prove this knowledge, dissipate the reservations and win the trust of the user. This and independent measurements by the Institut für Luftund Kältetechnik convinced the client to award the contract to Parker.
The client is very satisfied with the performance and maintenance intervals of the system, especially as they clean the filter elements on-site and reuse the filter inserts.
Watch this video to learn more about Smoghog:
This article was contributed by the Filtration Team.
Thanks to Dr. Truschka and the company for approving this article and the pictures. Authors: Carlo Saling, Norbert Jedrzejak and Jörn Jacobs
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Parker was recently approached by ENERAZ LLC, engineering subcontractor of Azpetrol Ltd. LLC and the biggest operator of filling stations in Azerbaijan, to provide several site-critical CNG distribution tube lines for the brand new CNG bus filling station in Baku.
Fitted with 14 CNG dispensers, 6 CNG compressors, 3 gas dryers and 3 chillers, the CNG filling station, which is located in the Narimanov district of Baku city, will be used by 300 buses of BakuBus LLC.
Leak-free gas distribution lines for a safer environment.Nearly 2,000 metres of Parker seamless tubes together with A-LOK® two ferrule tube fittings manufactured by Parker Instrumentation Products Division, Europe are among the key components to have been fitted onsite.
“As with all high-pressure gas fuelling systems, ensuring environmentally-safe CNG distribution was one of the main priorities for Azpetrol. This is something we’ve been able to guarantee by providing tubes and fittings that have been specifically designed to provide leak-free connections along the highly pressurised distribution lines.”
Murad Jafarov, Parker’s Azerbaijan Area Manager.
Image. 1. Parker's A-LOK® two ferrule fittings and tubing installed on three CNG compressors at the fuelling station.
Superior corrosion resistance.Not only do Parker’s CNG components guarantee leak-free distribution, they’ve been manufactured to withstand the corrosive effect of being exposed to the elements over a sustained period of time. The components are also robust enough to withstand the vibrations generated when the tube lines are being used.
“While this may have been the first time we’ve worked with Parker, we were aware of their products on board CNG vehicles, as well as within the wider CNG refuelling infrastructure across the world, which now includes Azerbaijan’s newest bus filing station. Having Parker’s components onsite has provided us with peace of mind that the risk of gas leaks, and the associated environmental impact is being kept to an absolute minimum now, and for many years to come.”
Elchin Mammadov, Head of Supply Department at Azpetrol.
Image. 2. A-LOK® two ferrule fitting with unique SuparcaseTM ferrule treatment offers excellent corrosion resistance and vibration protection.
Learn more about Parker Instrumentation Products Division's natural gas solutions for the transportation industry.
Article contributed by:
Murad Jafarov, Azerbaijan Area Manager, Parker Sales Company Central & Eastern Europe
Dave Edwards, Fittings Product Manager, Parker Hannifin Manufacturing, Instrumentation Products Division, Europe.
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Four Key Factors to Consider When Selecting Instrumentation Tubing
Do you need to detect ferrous wear particles in machinery? Are you working remotely, onboard a vessel, or onsite in a less than ideal environment? Ferrous wear meters allow users to measure ferrous wear debris in oil samples for condition monitoring in both marine engines and lubricated machinery.
Detecting metal particles
The Parker Ferrous Wear Meter (FWM) is a simple, easy-to-use instrument that provides accurate, reliable detection of metal particles in oil samples taken from a variety of types of machinery, including used cylinder scrape down oil, gearboxes and bearings. Monitoring of ferrous wear levels with your oil samples on an ongoing basis allows any deterioration in machine condition to be quickly spotted and corrective action taken, saving you downtime and money, and preventing more serious damage occurring. This versatile unit is ideal for testing and analysing oil samples on-site, on-board or in remote locations where full laboratory analysis is not possible.
Features include:
The FWM is constructed using a sophisticated magnetometer adapted for field applications. A 5-millilitre test tube, filled with the sample, is placed directly in the hole in the instrument and its metallic content, in PPM, is displayed on the screen in less than 2 seconds.
By taking ferrous wear measurements over time, any increase in wear levels can be monitored and appropriate actions taken to mitigate any damage. Machinery degradation can be observed as it happens and machines serviced as and when they need to be, rather than on a time or hours of operation basis, saving costs and manpower.
Performing a ferrous wear test
Each ferrous wear meter is supplied with three check standards to verify the product on a regular basis. In this example,
the 972 - 922 PPM ferrous content sample is being used.
Step 1
As per the on-screen instructions, insert the sample into the FWM for approximately one second, then remove. The result will be displayed on the screen for comparison against the check standard.
Step 2
Step 3
Insert the oil sample into the ferrous wear meter for approximately 1 second. Then remove.
Step 4
The results will display shortly after removal.
Watch this step by step video for complete instructions:
To learn more about the Parker Ferrous Wear Meter, download our datasheet.
Please visit our Hydraulic and Industrial Process Filtration Division EMEA for additional information.
This post was contributed by the Hydraulic Filtration Team.
Find more related articles here:
Optimising Feed Rate in the Fight Against Cold Corrosion
The Importance of Condition Monitoring to Your Business
Meeting New Sulphur Limits for Marine Fuel Oil
Bunker Quality: Why Changes to ISO 8217 Increase the Need for Condition Monitoring
Do you need to detect ferrous wear particles in machinery? Are you working remotely, onboard a vessel, or onsite in a less than ideal environment? Ferrous wear meters allow users to measure ferrous wear debris in oil samples for condition monitoring in both marine engines and lubricated machinery.
Detecting metal particles
The Parker Ferrous Wear Meter (FWM) is a simple, easy-to-use instrument that provides accurate, reliable detection of metal particles in oil samples taken from a variety of types of machinery, including used cylinder scrape down oil, gearboxes and bearings. Monitoring of ferrous wear levels with your oil samples on an ongoing basis allows any deterioration in machine condition to be quickly spotted and corrective action taken, saving you downtime and money, and preventing more serious damage occurring. This versatile unit is ideal for testing and analysing oil samples on-site, on-board or in remote locations where full laboratory analysis is not possible.
Features include:
The FWM is constructed using a sophisticated magnetometer adapted for field applications. A 5-millilitre test tube, filled with the sample, is placed directly in the hole in the instrument and its metallic content, in PPM, is displayed on the screen in less than 2 seconds.
By taking ferrous wear measurements over time, any increase in wear levels can be monitored and appropriate actions taken to mitigate any damage. Machinery degradation can be observed as it happens and machines serviced as and when they need to be, rather than on a time or hours of operation basis, saving costs and manpower.
Performing a ferrous wear test
Each ferrous wear meter is supplied with three check standards to verify the product on a regular basis. In this example,
the 972 - 922 PPM ferrous content sample is being used.
Step 1
As per the on-screen instructions, insert the sample into the FWM for approximately one second, then remove. The result will be displayed on the screen for comparison against the check standard.
Step 2
Step 3
Insert the oil sample into the ferrous wear meter for approximately 1 second. Then remove.
Step 4
The results will display shortly after removal.
Watch this step by step video for complete instructions:
To learn more about the Parker Ferrous Wear Meter, download our datasheet.
Please visit our Hydraulic and Industrial Process Filtration Division EMEA for additional information.
This post was contributed by the Hydraulic Filtration Team.
Find more related articles here:
Optimising Feed Rate in the Fight Against Cold Corrosion
The Importance of Condition Monitoring to Your Business
Meeting New Sulphur Limits for Marine Fuel Oil
Bunker Quality: Why Changes to ISO 8217 Increase the Need for Condition Monitoring
Carbon dioxide (CO2), a colorless, odorless, noncombustible gas, is widely used in the food and beverage industry during the bottling process as a carbonation agent for soft drinks, beer and sparkling water. CO2 is at risk of contamination from leaks, insufficient processing, transportation, storage and handling, all of which can take place multiple times before reaching its point of use in the production plant. Contamination is a real problem for manufacturers as it can result in off-flavors and odors, spoilage, changes in appearance, product recalls and damaged reputation. That's why many beverage producers are taking measures — such as installing a Parker PCO2 Quality Incident Protection System — to ensure CO2 purity and avoid the serious impact of quality incidents on their businesses.
To help you learn more about the Parker PCO2 system, we've compiled a list of our top frequently asked questions.
Top FAQs on the PCO2 Quality Incident Protection System 1. What is PCO2?
The PCO2 is a static adsorption bed constructed from specially selected adsorbents that are designed to remove trace contamination from CO2 to guarantee gas quality so it remains within industry and company guidelines. The system prevents detrimental consequences to the finished end beverage, the producer's reputation, and their bottom-line.
The PCO2 designed as a quality incident protection device, meaning that it will treat out-of-specification CO2 to return it back to specification (within the limits of the specification). The PCO2 is not designed to constantly purify poor quality CO2 (not allowing the beverage producer to lower the incoming CO2 specification).
CO2 is produced from a wide variety of processes with differing contaminants. Some of these remain in the gas after treatment at the gas recovery plant. There have been some publicised incidents where poor quality gas passed all the way through the supply chain and into the beverage. To prevent a repeat occurrence of these quality incidents, bottlers are implementing in-line, on-site protection, in addition to tightening controls at the CO2 suppliers.
This is where a delivery of out-of-specification CO2 has been made to the plant or where CO2 has been contaminated on-site during the production process and fails to meet recommended standards.
ISBT (International Society of Beverage Technologists) & EIGA (European Industrial Gas Association) both have International recommended standards. In these standards, potential contaminants are named with a critical PPM limit of acceptance.
The PCO2 purifier will treat CO2 with up to 10 times the ISBT / EIGA levels of the named contaminants for a specified quantity of processed CO2 gas.
Many plants will find this very hard to observe if they do not have a CO2 analyser or gas inspection process on site. Most plants take the quality assurance (QA) certificate from the gas supplier as their goods inwards inspection. To improve monitoring of gas quality, many plants are purchasing online CO2 analysers in addition to purifiers.
In most cases, the gas will be clean and have very low levels of monitored contaminants. Under these conditions, there will be very little difference between inlet and outlet concentrations. In the event of a contamination spike, the purifier will remove it.
Yes, always.
All producers and bottlers of beverage products, including:
The three-layered adsorbent bed adsorbs contamination as it flows through. The three materials preferentially adsorb differing contaminants thus providing effective protection against a wide spectrum of potential contaminants.
No, although some companies may claim to be able to recover adsorbents and regenerate them, we are trying to remove contaminants to parts per billion levels and any trace residues may inhibit future performance. Additionally, many industrial processes for regenerating adsorbents ay actually add contamination to the PCO2 cartridges.
The purifier treats vapour phase CO2, so it has to be installed downstream of the vaporiser (evaporator), with a maximum approach temperature of 40°C. Some plants have installed the purifiers close to the carbonator, while others have chosen a central point close to the evaporator for complete site treatment. The Parker PCO2 is suitable for either option. The PCO2 is also suitable for external installation.
This blog was contributed by Danny Silk, product manager, specialist filtration, Parker Gas Separation and Filtration Division, EMEA.
Related content
CO2 Quality Incident Protection for Fountain Drink Dispense
The Importance of Maintaining CO2 Gas Quality in Bottling Applications | Case Study
Carbon dioxide (CO2), a colorless, odorless, noncombustible gas, is widely used in the food and beverage industry during the bottling process as a carbonation agent for soft drinks, beer and sparkling water. CO2 is at risk of contamination from leaks, insufficient processing, transportation, storage and handling, all of which can take place multiple times before reaching its point of use in the production plant. Contamination is a real problem for manufacturers as it can result in off-flavors and odors, spoilage, changes in appearance, product recalls and damaged reputation. That's why many beverage producers are taking measures — such as installing a Parker PCO2 Quality Incident Protection System — to ensure CO2 purity and avoid the serious impact of quality incidents on their businesses.
To help you learn more about the Parker PCO2 system, we've compiled a list of our top frequently asked questions.
Top FAQs on the PCO2 Quality Incident Protection System 1. What is PCO2?
The PCO2 is a static adsorption bed constructed from specially selected adsorbents that are designed to remove trace contamination from CO2 to guarantee gas quality so it remains within industry and company guidelines. The system prevents detrimental consequences to the finished end beverage, the producer's reputation, and their bottom-line.
The PCO2 designed as a quality incident protection device, meaning that it will treat out-of-specification CO2 to return it back to specification (within the limits of the specification). The PCO2 is not designed to constantly purify poor quality CO2 (not allowing the beverage producer to lower the incoming CO2 specification).
CO2 is produced from a wide variety of processes with differing contaminants. Some of these remain in the gas after treatment at the gas recovery plant. There have been some publicised incidents where poor quality gas passed all the way through the supply chain and into the beverage. To prevent a repeat occurrence of these quality incidents, bottlers are implementing in-line, on-site protection, in addition to tightening controls at the CO2 suppliers.
This is where a delivery of out-of-specification CO2 has been made to the plant or where CO2 has been contaminated on-site during the production process and fails to meet recommended standards.
ISBT (International Society of Beverage Technologists) & EIGA (European Industrial Gas Association) both have International recommended standards. In these standards, potential contaminants are named with a critical PPM limit of acceptance.
The PCO2 purifier will treat CO2 with up to 10 times the ISBT / EIGA levels of the named contaminants for a specified quantity of processed CO2 gas.
Many plants will find this very hard to observe if they do not have a CO2 analyser or gas inspection process on site. Most plants take the quality assurance (QA) certificate from the gas supplier as their goods inwards inspection. To improve monitoring of gas quality, many plants are purchasing online CO2 analysers in addition to purifiers.
In most cases, the gas will be clean and have very low levels of monitored contaminants. Under these conditions, there will be very little difference between inlet and outlet concentrations. In the event of a contamination spike, the purifier will remove it.
Yes, always.
All producers and bottlers of beverage products, including:
The three-layered adsorbent bed adsorbs contamination as it flows through. The three materials preferentially adsorb differing contaminants thus providing effective protection against a wide spectrum of potential contaminants.
No, although some companies may claim to be able to recover adsorbents and regenerate them, we are trying to remove contaminants to parts per billion levels and any trace residues may inhibit future performance. Additionally, many industrial processes for regenerating adsorbents ay actually add contamination to the PCO2 cartridges.
The purifier treats vapour phase CO2, so it has to be installed downstream of the vaporiser (evaporator), with a maximum approach temperature of 40°C. Some plants have installed the purifiers close to the carbonator, while others have chosen a central point close to the evaporator for complete site treatment. The Parker PCO2 is suitable for either option. The PCO2 is also suitable for external installation.
This blog was contributed by Danny Silk, product manager, specialist filtration, Parker Gas Separation and Filtration Division, EMEA.
Related content
CO2 Quality Incident Protection for Fountain Drink Dispense
The Importance of Maintaining CO2 Gas Quality in Bottling Applications | Case Study
Compressive Stress Relaxation (CSR) is a means of estimating the service life of a rubber seal over an extended period of time. As such, it can be thought of as the big brother of compression set testing. Rather than measuring the permanent loss of thickness of a compressed rubber specimen as is done in compression set, CSR testing directly measures the load force generated by a compressed specimen and how it drops over time. In part 1 of our blog series, we will explore the theory of CSR testing, common test methods, and how CSR differs from compression set testing.
Theory of CSR Testing
To understand the value of CSR testing and how it differs from compression set testing, it is helpful to return to the basic theory of how a rubber seal functions. In a standard compressed seal design, a rubber seal is deformed between two parallel surfaces to roughly 75% of its original thickness. Because the material is elastic in nature, the seal pushes back against the mating surfaces, and this contact force prevents fluid flow past the seal, thus achieving a leak-free joint. Over time, the material will slowly (or perhaps not so slowly) relax. The amount of force with which the seal pushes against the mating surfaces will drop, and the seal will become permanently deformed into the compressed shape. In compression set testing, the residual thickness of the specimen is measured, and it is assumed that this residual thickness is valid proxy for the amount of residual load force generated by the compressed seal. In CSR testing, the residual load force is measured directly.
In practice, CSR results are typically presented very differently from compression set results. In CSR testing, it is common to see multiple time intervals over a long period of time (3,000 hours or more of testing), thus allowing a curve to be created (see Figure 1). In practice, however, specifications are written such that only the final data point has pass/fail limits. In compression set testing, it is common to see a single data point requirement with a single pass/fail limit. Multiple compression set tests can be performed to create a curve, but this is almost always down for research purposes rather than for specification requirements. In most cases, compounds that excel in compression set resistance also demonstrate good retention of compressive load force over time. However, there are exceptions.
Figure 1: Typical CSR curve.
These results display a fluorocarbon seal material immersed in engine oil at 150°C.
CSR Test Methods
CSR testing can be quite complicated, and caution is needed when comparing reports to ensure a valid apples-to-apples comparison can be made. As with compression set, CSR testing can be performed in air or immersed in a fluid. Because most seal materials will oxidize in the presence of hot air, the results for CSR in air can be strikingly different (worse) than the results for CSR in a fluid at the same temperature. In addition to time and temperature, the sample size (usually a button 12.7 mm in diameter and 6.35 mm thick) and amount of compression (typically 25%) must be the same to make a valid comparison.
There are multiple test procedures and fixture designs within the CSR test world that also have a significant impact on results. Numerous fixture designs exist, all of which produce different results. Regardless of Hornig’s1 conclusions regarding his preferred fixture, in practice, most CSR data for elastomer seal materials is gathered with a “Dyneon-modified Wykeham-Farrance” jig (see image).
Finally, CSR force measurements can be made intermittently at discreet time points using a standalone compressive load cell or continuously using a dedicated CSR testing device that incorporates a load cell for each test fixture and one or more integrated environmental chambers. With the intermittent test method, fixtures are removed from the oven and/or oil bath, allowed to cool to room temperature (23°C), manually tested on a compressive load cell, and returned to the oven for additional aging. Continuous testing does not involve this repeated thermal cycling, which contributes to accelerated relaxation and worse results. As a result, intermittent CSR generally appears worse than continuous CSR for the same material under the same conditions. In addition, continuous CSR data points are gathered at the test temperature rather than at room temperature. Gathering load force data at elevated temperatures results in a higher measured load force; when compared to an initial load force data point taken at room temperature, as some procedures require. This can result in a counterintuitive situation whereby it appears that a material initially improves with thermal aging. (See Figure 2.) If this is observed, it should be considered an artifact of the difference in test temperature. When comparing CSR results, it is absolutely essential to confirm that the same test method and fixture were used for both tests.
Watch for part 2 of this series, where we will explore some of the powerful insights that can be gleaned through CSR curve interpretation. For more information or assistance with your sealing challenges, contact our applications team at oesmailbox@parker.com or chat with us online at the Parker O-Ring & Engineered Seals Division website.
References:
1. Hornig, R. Comparison of various CSR methods regarding the static long-term sealing behaviour of AEM, ACM and HNBR compounds, International Polymer Science and Technology, 37, No. 4, 2009.
This article contributed by Dan Ewing, senior chemical engineer, Parker Hannifin O-Ring Division.
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Reduce Downtime and Costly Seal Replacements: Seal Failure Diagnosis Part 1
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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.
When an extended shaft makes sense
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 offerings
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.
Conclusion
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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Understanding Why There are So Many Options for Mounting a PTO
How to Specify a Power Take-Off (PTO)
Ten Frequently Asked Questions You Should Know About PTOs
This is a very exciting time to be in Manufacturing! Manufacturing Engineers’ toolboxes are expanding everyday with new technologies and possibilities for greater efficiency and capability. The Fourth Industrial Revolution, or what some are calling Industry 4.0, is bringing all kinds of tools to bear on all processes in our industrial world. The next step in embracing this revolution is making sure that Manufacturing Engineers are exposed to and educated on what is possible.
What tools should be included in your toolbox?
In 2017 Parker opened a new state-of-the-art Advanced Manufacturing Learning and Development Center (AMLDC), located at our Parker Technology Center facility in Macedonia, Ohio. The AMLDC facility serves as a center of excellence where Parker engineers can explore new applications of emerging technologies such as additive manufacturing and collaborative robotics.
The investment in cutting-edge additive manufacturing equipment is driven by the tremendous long-term value of these technologies. By creating a single facility near its global headquarters in Northeast Ohio, Parker is providing its operating groups and divisions around the world with access to the newest printers, software and materials available.
By utilizing central resources, Parker will leverage its investment and allow Parker engineers globally to better solve our customers’ challenges. With the ability to create multiple configurations of a single component without developing additional molds or customized tooling, additive manufacturing has emerged as a quick and inexpensive prototyping solution. This translates into speed in addressing the unique challenges of customers, providing engineers with the ability to create custom products and systems faster than ever before.
“Material science is foundational for new process and product development.”
Robert Pelletier, engineering manager for Parker’s AMLDC
Parker's Paul Susalla, corporate manufacturing technology advancement director, feels that certain technologies are first for all manufacturing companies to consider. These include
Robotics
Low unemployment today has created a situation of not having enough qualified applicants to fill job openings. Robotic automation, both collaborative and traditional industrial, provides an opportunity to mitigate this issue. More and more, employees are seeing this as less of a threat and more of an opportunity to avoid the jobs they do not like with the ability to do more interesting and complex work. Implementing Lean practices and hosting Kaizen events prior to implementation help avoid automating bad processes. Benefits of greater efficiency, consistency, quick return on investment and the inherent data available for DDM make automation a must-do.
Whether adding sight to robots or used for visual inspection or sorting, vision has come a long way in the past few years. Updates and new options for high resolution 2D cameras, 3D visual systems, laser line scanners and random robotic bin picking solutions are coming out with increasing velocity. The quality of the systems today not only ease the strain on employees but make robust the application of Zero Defect Manufacturing (ZDM) utilizing No Faults Forward (NFF) approaches.
AR takes on many forms from station or warehouse scale projection systems to wearables. This rapidly expanding technology presents additional data and instruction to the user within their view of the real world which creates opportunities like never before. Imagine the time savings for training new operators! Instead of working with a new employee on their assembly tasks for several hours, the new operator starts directly at their workstation and follows the directions presented; parts to pick up are highlighted, how-to videos are run, and their motions are tracked for correctness. This non-intrusive system trains the new employee while not limiting the experienced team member, provides real motion data for DDM and enables NFF on manual operations. In high-mix / low-volume operations, it can dramatically improve output quality by making sure things are done properly every time.
Virtual Reality (VR)The complete immersion in the 3D simulation now allows global engineering teams to collaborate and review designs and systems that exist only on a computer without having to leave their facilities. The teams can interact, walk around, mark up changes and work together as if they were together in the same room around real hardware.
Additive Manufacturing (AM)
3D printing is re-writing the rules of how to design and make things. AM is not only used for prototyping and manufacturing trials (machine interference, CMM teaching, fluid studies…) but additionally for tooling, fixtures and gauges. These are being produced in great numbers. Created in very short time at minimal cost, these items can be iterated and optimized for the parts and application. Production parts are always the desire. Metal and many polymer systems produce parts suitable for end use. Design technologies are catching up with our abilities to “grow” parts. Generative Design / Topology Optimization are technologies where the computer uses loads, torques, envelope and constraints provided by the engineer to evolve the design. It does this through multitudes of iterations and presents functional geometry options at minimal weight that may not have occurred to the user.
Many manufacturing challenges still rely on people. Difficult inspection processes or operations with a great deal of variability of parts require the intelligence of people to make decisions. Optimization of machine cycles and robot motion today may only be taken so far due to human limitations. The capabilities of AI and Machine Learning are expanding at a fast pace and will soon be one more common tool in a Manufacturing Engineer’s toolbox to take on these and other tasks. These technologies are good at finding the anomaly and working through multitudes of trials to find the right solution. As processing power increases, so will the application of these technologies.
What's not to love about manufacturing?This rapidly expanding world of manufacturing technologies and capabilities is truly exciting. Manufacturing Engineers have always found developing new processes and manufacturing systems to be rewarding. With new tools and technologies repeatedly becoming available, how could anyone not become even more enamored with this profession?
Looking to join us and start your own career in manufacturing? View our open manufacturing positions at Parker Careers.
Certainly, pride in one's work, innovative thinking and a shared sense of Purpose are the hallmarks of our most critical engineering breakthroughs and most significant achievements. How do partnerships enable breakthroughs? After more than a century of experience serving our customers, Parker is often called to the table for the collaborations that help to solve the most complex engineering challenges. We help them bring their ideas to light. We are a trusted partner, working alongside our customers to enable technology breakthroughs that change the world for the better. Learn more about Parker Leading with Purpose on our webpage.
Article contributed by Paul Susalla, corporate manufacturing technology advancement director, Parker Hannifin
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When compared to bacterial contamination, Mycoplasma contamination isn't immediately obvious.
The outcome of any contamination event is the same — the disposal of the contaminated media and decontamination of equipment used in the process — but the methods of detection and the timelines differ enormously.
You would know if a culture was contaminated with bacteria within 24 hours: the contamination would be obvious — as would the need to immediately remove and dispose of the culture.
Mycoplasma's secret weaponMycoplasma contamination, however, presents a different scenario. A culture could have a Mycoplasma infection at as much as 10,000 Mycoplasma per mammalian cell, with no detectable effect.
Mycoplasma stays under the radar and co-exists with a cell line, with no immediately visible side effects. There is no change in the media appearance, or in the pH or DO demand. What will happen is that the Mycoplasma will compete for nutrients at a low level, resulting in potentially slower cell growth and lower yields.
As well as depleting the nutrient supply, the Mycoplasma's metabolic activity will result in the release of toxic and/or cytolytic metabolites which will have a negative effect on the cells.
The results? Production levels could be lower than expected and R&D decisions could be made based on compromised data, due to an undetected Mycoplasma infection affecting cell growth and productivity.
If you'd like to learn more about Mycoplasma contamination and how to tackle it read our white paper: Preventing Mycoplasma Contamination
How the wider supply chain is affected
A Mycoplasma contamination event can have serious consequences for patient safety as it can disrupt supply of critical drug products. It will result in unplanned downtime, leading to disruption in the supply chain causing reputational damage and financial consequences.
From an operational perspective, Mycoplasma contamination will lead to an investigation and remedial works, all followed by the cleaning in place (CIP) / sterilizing in place (SIP) of fixed assets. If a facility is using single-use systems, CIP and SIP won't be needed, however, the entire site will still need to be decontaminated.
So what options are available for testing? Direct culture on agarThis is the classic method for detecting a Mycoplasma contamination and is the regulatory test to show clearance for clinical use.
While this test is effective and sensitive, it is the most difficult and time-consuming method - it takes 28 days for results to be obtained. This method also requires live Mycoplasma cultures to be maintained to act as positive controls. However, bearing in mind how easily Mycoplasma can spread, this may not be something that is advisable to have in the same building as a cell culture lab. As a result, this test tends to be outsourced — which further extends the time taken for a result to be attained.
PCRPCR is a sensitive and analytical testing method. It is relatively quick and effective in detecting contaminations which can be difficult to spot. However, it can't distinguish between viable and non-viable organisms. In addition, to avoid giving false-positive results, the testing laboratory must implement strict measures to ensure containment to prevent cross-contamination and environmental contamination.
DNA fluorochrome stainingThis is a simple and fast method that stains DNA using a fluorescent dye which can then be viewed under a fluorescence microscope. It requires positive and negative controls and while in normal circumstances, the requirement for positive controls would count against a method, these controls are commercially available. And as the Mycoplasma have already been fixed onto slides, they present no contamination risk to the lab.
ELISA testingEnzyme-linked immunosorbent assay (ELISA) is a technique used to detect infectious agents in a sample. This form of testing can yield quick results, however, it may not be able to detect uncommon sources of contamination.
But which is the best practice?Best practice (and that required by the FDA) is a combination of the direct culture method (given its high sensitivity) and DNA Fluorochrome testing, which will detect low-level fastidious Mycoplasma contaminations.
So how can Mycoplasma be eliminated?Once identified, you must eliminate any Mycoplasma infected material, solutions or equipment. An autoclave cycle will have a 100 percent success rate. But if a cell line is unique and you cannot afford to lose it, you have no option but to try to recover the cell line.
You could turn to antibiotics — but that should be a last resort and only used if a highly valuable or unique cell line can't be thrown away. The process lasts for a number of weeks and antibiotics may also be detrimental to the cells, resulting in the loss of the culture you are trying to preserve.
Once treatment with antibiotics is complete, thorough screening is required to ensure that contamination has been eliminated and not just suppressed.
Tetracyclines, macrolides and fluoroquinolones can be used, but their use should be limited to avoid resistance.
All equipment should be decontaminated either by SIP or autoclave cycles. Disinfectants that target Mycoplasma are also available. If it is not possible to apply these methods after suspected contamination, any equipment needs to be removed from the facility and replaced.
To avoid cross-contamination events, media and reagents should only be used for one cell line and never stored in the laminar flow hood. Any media and reagents that have been near a contaminated culture should be disposed of immediately.
Implementing a system to isolate cell lines, reagents and equipment — combined with good housekeeping procedures — should help to prevent contamination from spreading.
Prevention is always better than cure
The key is knowing the source of the cells, using media from reputable sources and following a good aseptic technique.
When looking at a mitigating risk from media and components that are heat labile, a particularly successful method is filtration using a 0.1 micron rate membrane such as Parker Bisocience Filtration's PROPOR MR.
Incorporating a highly retentive 0.1 micron PES membrane, PROPOR MR filters provide fast and effective removal of Mycoplasma from cell culture media.
If you'd like to learn more about Mycoplasma contamination and how to tackle it read our white paper: Preventing Mycoplasma Contamination
This post was contributed by Guy Matthews, division marketing manager, 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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As mentioned in part one of our seal failure blog series, O-ring and seal failures are often due to a combination of failure modes, making root cause difficult to uncover. It's important to gather hardware information, how the seal is installed, application conditions, and how long a seal was in service before starting the failure analysis process. In part 1 of our blog series, we discussed compression set, extrusion and nibbling, and spiral failure. In part 2 of our series, we will review four other common failure modes to familiarize yourself with before diagnosing a potential seal failure in your application.
Rapid Gas Decompression
Rapid gas decompression (commonly called RGD, or sometimes explosive decompression (ED)) is a failure mode that is the result of gas that has permeated into a seal that quickly exits the seal cross section, causing damage.
Detection of this failure mode can be difficult, as the damage does not always show on the exterior. When the damage is visible, it can look like air bubbles on out the outside, or perhaps a fissure that has propagated to the surface. The damage may also be hidden under the surface. If the seal is cut for a cross section inspection, RGD damage will look like fissures in the seal that may or may not propagate all the way to the surface.
Parker’s guidance as to how to avoid this failure mode is: 1) Keep the depressurization rate lower than 200 psi per minute. If this cannot be achieved, we would suggest 2) RGD resistant materials. We offer these RGD resistant options from the HNBR, FKM, EPDM, and FFKM polymer families.
Abrasion damage is the result of the seal rubbing against a bore or shaft, resulting in a reduction of cross sectional thickness due to wear. As the seal wears, it has the potential to lose compression on the mating surface. This wear is compounded by the fact that dynamic applications already have lower compression recommendations.
To reduce risk for this failure mode, it requires consideration during design and seal selection. The surface finish and concentricity of the hardware will be very important considerations. A smooth surface results in less friction (suggest 8 to 16 RMS), which in turn results in less wear. Increasing the durometer of the seal material helps resist wear, and there are also internally lubricated materials that could be employed. If the application is high temperature, one should consider the impacts of thermal expansion on the elastomer being used. The thermal expansion increases contact pressure, which would increase friction / wear.
Installation Damage
Installation damage can occur in both face seals and radial seals but is much more common in radial applications. Installation damage can be the result of excessive installation stretch, cuts or nicks from installation tools, the installation of a seal over a burr or sharp corner or threads, improper size selection, or the insertion of a piston into a bore that does not employ an appropriate lead in chamfer.
Our guidance for avoiding this failure mode is to:
• Break all sharp corners.
• Provide a 20 degree lead in chamfer for radial seal applications.
• Cover threads that the seal will travel over during installation.
• Use lubrication during installation (this is the main benefit of an externally applied lubricant).
Fluid incompatibility
A failure due to fluid compatibility issues will usually be evident upon disassembly of hardware after the seal has been in service. Fluid incompatibility can look like many things but will be the result of some sort of chemical attack on the seal itself. The seal could be excessively swollen, from absorbing service fluid(s), softened or gummy which would likely lead to another failure mode such as extrusion or compression set, cracking / embrittlement, or a simple case of rapid compression set.
This failure mode is one that can be completely avoided by selecting an appropriate material for a given application. Parker offers several tools to help guide to proper material family selection in our O-Ring handbook (chapter 7), as well as our e-handbook and mobile InPhorm. We also have our live chat feature, where you can run a specific application by the Applications Engineering team.
In addition to the materials mentioned above, Parker provides numerous other resources to support the diagnosis of seal failures and the best sealing solutions. Check out our latest tech webinar on seal failures modes or utilize our leak troubleshooting app. You can also visit our website for resources under our Solutions area for more tools and assistance.
This article was contributed by William Pomeroy, applications engineer, Parker O-Ring & Engineered Seals Division.
Reduce Downtime and Costly Seal Replacements: Seal Failure Diagnosis Part 1
3 Guidelines to Ensure Proper Seal Installation
A Simple Guide to Radial Seals | Sealing Fundamentals
As mentioned in part one of our seal failure blog series, O-ring and seal failures are often due to a combination of failure modes, making root cause difficult to uncover. It's important to gather hardware information, how the seal is installed, application conditions, and how long a seal was in service before starting the failure analysis process. In part 1 of our blog series, we discussed compression set, extrusion and nibbling, and spiral failure. In part 2 of our series, we will review four other common failure modes to familiarize yourself with before diagnosing a potential seal failure in your application.
Rapid Gas DecompressionRapid gas decompression (commonly called RGD, or sometimes explosive decompression (ED)) is a failure mode that is the result of gas that has permeated into a seal that quickly exits the seal cross section, causing damage.
Detection of this failure mode can be difficult, as the damage does not always show on the exterior. When the damage is visible, it can look like air bubbles on out the outside, or perhaps a fissure that has propagated to the surface. The damage may also be hidden under the surface. If the seal is cut for a cross section inspection, RGD damage will look like fissures in the seal that may or may not propagate all the way to the surface.
Parker’s guidance as to how to avoid this failure mode is: 1) Keep the depressurization rate lower than 200 psi per minute. If this cannot be achieved, we would suggest 2) RGD resistant materials. We offer these RGD resistant options from the HNBR, FKM, EPDM, and FFKM polymer families.
Abrasion damage is the result of the seal rubbing against a bore or shaft, resulting in a reduction of cross sectional thickness due to wear. As the seal wears, it has the potential to lose compression on the mating surface. This wear is compounded by the fact that dynamic applications already have lower compression recommendations.
To reduce risk for this failure mode, it requires consideration during design and seal selection. The surface finish and concentricity of the hardware will be very important considerations. A smooth surface results in less friction (suggest 8 to 16 RMS), which in turn results in less wear. Increasing the durometer of the seal material helps resist wear, and there are also internally lubricated materials that could be employed. If the application is high temperature, one should consider the impacts of thermal expansion on the elastomer being used. The thermal expansion increases contact pressure, which would increase friction / wear.
Installation Damage
Installation damage can occur in both face seals and radial seals but is much more common in radial applications. Installation damage can be the result of excessive installation stretch, cuts or nicks from installation tools, the installation of a seal over a burr or sharp corner or threads, improper size selection, or the insertion of a piston into a bore that does not employ an appropriate lead in chamfer.
Our guidance for avoiding this failure mode is to:
• Break all sharp corners.
• Provide a 20 degree lead in chamfer for radial seal applications.
• Cover threads that the seal will travel over during installation.
• Use lubrication during installation (this is the main benefit of an externally applied lubricant).
Fluid incompatibility
A failure due to fluid compatibility issues will usually be evident upon disassembly of hardware after the seal has been in service. Fluid incompatibility can look like many things but will be the result of some sort of chemical attack on the seal itself. The seal could be excessively swollen, from absorbing service fluid(s), softened or gummy which would likely lead to another failure mode such as extrusion or compression set, cracking / embrittlement, or a simple case of rapid compression set.
This failure mode is one that can be completely avoided by selecting an appropriate material for a given application. Parker offers several tools to help guide to proper material family selection in our O-Ring handbook (chapter 7), as well as our e-handbook and mobile InPhorm. We also have our live chat feature, where you can run a specific application by the Applications Engineering team.
In addition to the materials mentioned above, Parker provides numerous other resources to support the diagnosis of seal failures and the best sealing solutions. Check out our latest tech webinar on seal failures modes or utilize our leak troubleshooting app. You can also visit our website for resources under our Solutions area for more tools and assistance.
This article was contributed by William Pomeroy, applications engineer, Parker O-Ring & Engineered Seals Division.
Reduce Downtime and Costly Seal Replacements: Seal Failure Diagnosis Part 1
3 Guidelines to Ensure Proper Seal Installation
A Simple Guide to Radial Seals | Sealing Fundamentals
Since the advent of the semi-automatic water conditioning control valve followed by the automatic control valve, a common weakness has been the brine tubing connections between the brine valve and the brine tank. This circuit functions in two ways and is exposed to both a vacuum during the brine draw cycle and water pressure during a refill. A loose-fitting at either of these locations would cause loss of vacuum and/or a water leak, neither of which is acceptable and the result is often an unscheduled service call.
Results of poor connections during brine draw
Brine is drawn from the brine tank when the control valve cycles to provide motive flow and pressure to the injector assembly (venturi) in the control valve while simultaneously opening the drain line to allow displacement of the accumulated hardness and metals from the resin bed during the service run. An injector consists of a nozzle and throat. The injector is selected based on the size of the media tank square foot (ft2) surface area. A venturi combines a narrow tube called a nozzle that restricts the flow of water which increases the velocity and decreases the pressure of the water passing through it, creating a partial vacuum immediately after leaving the nozzle. As water passes through the injector nozzle, the high velocity creates a vacuum which draws the brine from the brine tank, mixing with the water as it enters the throat. The brine is mixed with the water to dilute the brine from 100% concentrated brine to a 30% concentration. This diluted brine is introduced into the resin bed where it releases the calcium and magnesium from the resin and flushes it to drain. Maintaining the proper mixture is very important to ensure optimal regeneration. If the brine draw is weak due to poor vacuum, the brine is diluted below 30% and the result is a partial regeneration and potential salty water to service after the regeneration cycle is complete. Further evidence of poor connections includes overflowing brine tank, where a complete loss of vacuum won’t permit brine draw. However, the brine refill cycle will add additional water to the brine tank which could result in an overflow condition. Different manufacturers offered what they thought was the best connector based on what was available at the time. Let’s look at some of the options that were available.
The different types of brine tube connections
Brass compression
Brass compression-style fittings were the most common and have been used for decades. In the early days, some valve manufacturers molded the 3/8” compression connection directly into the brass valve body produced at the foundry. The nuts, sleeves and tube supports were shipped with the valve to the assembler or were included with fully assembled softener/brine tank or cabinet style softeners. The brass compression-style connections are trusted for their dependable performance in virtually all conditions where temperatures range between 350 – 1200 F for domestic tap water applications. They also work very well for hot water softener applications where water temperatures can reach 1800 F. Attention to proper assembly is important because of the use of soft polyethylene or polypropylene tubing. Tube support is required to prevent distortion of the plastic tubing which guarantees effective gripping and a robust seal.
The connection is made by sliding the nut and sleeve onto the tubing, inserting the tube support into the plastic tube, inserting the tubing into the fitting until it’s bottomed on the seat, then tightening the nut until finger tight. The nut is then wrench-tightened with a specific number of wrench turns dictated by the specific fitting type and the size of the tubing. Based on their highly specific assembly instructions and the multiple components involved, brass compression-style fittings not only take time to assemble – around 40 seconds per connection – are labor-intensive - but also run the risk of being assembled incorrectly. For this reason, assemblers require some level of expertise when using this fitting type.
While brass compression fittings are viewed as highly dependable joint connections, with sealing performance that is second to none, higher labor costs are forcing manufacturers and assemblers to look for more cost-effective and less labor-intensive connection options.
Thermoplastic compression fittings
Plastic compression fittings have been used for over 40 years and vary in style and material composition. As with the brass compression-style fittings, tube support must be used with soft tubing. Plastic compression fittings are corrosion resistant and simple to install. The advantage is that there is no need to disassemble the fitting because all that is required is to cut the tubing square, insert tube support, insert into the fitting and hand tighten the ferrule nut to seal the connection. There is however a distinct disadvantage with these plastic fittings. They are prone to becoming loose with ambient temperature changes that coincide with seasonal weather patterns. Historically, it is necessary to retighten these plastic fittings to prevent the vacuum and water leaks previously mentioned.
Plastic Hose Barb Fittings
Plastic hose barb fittings are corrosion resistant and are not generally used for the brine valve connections. Typically, vinyl or polyurethane tubing or rubber hose is used with a hose clamp to ensure maximum grip and sealing power. Because vinyl or polyurethane or rubber hose is soft, it is subject to collapse during the vacuum phase of the brine draw cycle. Polyethylene tubing is not recommended because it will crack and leak.
Push-to-Connect Fittings
Push-to-Connect (PTC) plastic fittings for water service have been available since the mid-1980s. There are many companies that offer competitive products. Many of those products require a locking clip where a vacuum service is required to prevent the collet from retracting which allows the entrance of air. To combat this problem, some competitive products use a double “O”- Ring seal to solve vacuum-loss. The double “O”- Ring makes it harder to insert the tubing and unless full insertion depth is achieved by engaging both “O”- Rings, connection failure may result. Additionally, debris entrapment between the “O” – Rings may promote bacterial growth in the fluid stream. The problem of collet retraction may persist during vacuum service and therefore, a clocking clip may be required to prevent seal loss during vacuum.
An innovative alternative
Parker LIQUIfit fittings and one-piece cartridges feature a D-Seal that maintains a bubble-tight seal around the tubing to prevent liquid by-pass. The stainless-steel grab ring is fixed to the cartridge body which prevents the tubing from “pumping” or retracting during vacuum up to 28 inches of mercury (Hg) at room temperature without the need of a retaining clip.
The compact cartridge design allows machining or molding of a cavity for the cartridge which enables automation of manufacturing processes, reduces the labor cost of assembly, reduces leak paths, and gives your product or equipment a new, clean profile. By eliminating the need for threaded connections, tube connections are made quick and easy without the need or use of tools.
With Parker LIQUIfit, gone are virtually all labor costs associated with compression-style fittings and assembly time can be reduced by as much as 90%. Seasonal retightening of the plastic compression nuts due to temperature variations is no longer a concern. Hose clamps are no longer needed when using polyethylene tubing, and locking clips aren’t necessary to prevent retracting collets. LIQUIfit fittings and one-piece cartridges solve the challenges associated with other styles of brine tube connections and improve the integrity and reliability of your component, product, or system.
Attending WQA Convention and Exposition?
Visit us at WQA April 1-3, booth 638 to learn how Parker is improving operational efficiency and reducing costs for the commercial and residential water treatment market. The WQA Convention has been the signature event of the water treatment industry, connecting dealers, manufacturers, and consultants with the latest trends, research, education, and networking opportunities.
Post contributed by Gary Battenberg, technical support and systems design specialist with the Fluid System Connectors Division of Parker Hannifin. He has 35 years of experience in the fields of domestic, commercial, industrial, high-purity and sterile water treatment processes.
Related, helpful content for you:
Choosing the Right Connector, Tubing and Accessories for Your Application - Part 1
10 Steps to Cost Effective & Safe Installation of Instrumentation Tube and Fittings Systems. Part 2
Assembly Instructions for Ensuring Leak-Free O-ring Face Seal Fittings
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