Hydraulics

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

• Load

• Speed

• Cylinder motion (straight/fixed or pivot)

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

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

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

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

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

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

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

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

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

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

• Increased productivity through predictable maintenance and improved uptime

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

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

• Optimized efficiency in energy and fuel usage

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

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

• Comprehensive reporting for analysis and improvement

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

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

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

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

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

Ray Clapp, owner, Coast Range Construction

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

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

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

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

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

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

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

More product information can be found on PowerTilt here. 

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

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

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

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

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

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

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

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

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

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

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