Hydraulic News
This News Section is written and maintained by: Jewel Creative Ltd
July '10
Hardinge Machine Tools has announced that Greenway Pepper Precision Engineers has ordered the Bridgeport MV154 vertical machining centre to satisfy the production demands of a new contract.
The new contract will involve between 80 and 90 components/month being machined with cycle times up to an hour each.
Greg Pepper, managing director of Greenway Pepper, said: 'We used the Mach 2010 exhibition as a shop window to compare machines that would enable us to increase our machining capacity for a new contract.
'Bridgeport is well known to our production team as we already have five Bridgeport vertical machining centres (VMC) and a GX600 was installed last year.
'However, when we discussed the requirements for the new components, the MV154 provided the ideal specification with a good delivery,' he added.
In selecting the machine, the high levels of rigidity were an important factor.
For Greenway Pepper, the table loading of 500kg and dimensions of 900 x 500mm coupled with axis strokes of 700mm in X, 530mm in Y and 560mm in Z covered at the rates of 40, 40 and 36m/min and acceleration of 7, 6 and 5m/sec2 respectively were ideal.
The Bridgeport MV154 uses Heidenhain 620 control, which is familiar and therefore ideal to the needs of the shop floor and has a range of spindle options between 9,000 and 25,000rev/min.
It is able to deliver a torque of 187Nm, which will enable heavier-duty milling tasks.
Tools up to 76.2mm diameter can be held in the 30-position magazine, which can be increased to 125mm with adjacent pots being left empty.
Accuracy is high, at 0.008mm, helped by hand-scraped slide-ways; however, the machine specification can be improved to 4 micron by incorporating the linear encoder option.
Source: ManufacturingTalk
March '10
Parker Hannifin has brought out the D*1FP range of pilot-operated servo proportional valves.
These are based on the company's direct-operated DFplus hydraulics control valve, which features Parker's Voice Coil Drive (VCD) technology.
The VCD is based on the same principle used to vibrate loudspeaker diaphragms. Parker is using it to control the high forces within hydraulic valves. By producing dynamics on a par with modern servo valves, the VCD technology results in a much simpler valve structure. The new pilot-operated D*1FP series has transferred the advantages of the VCD to larger frame sizes and higher flow-rate valves.
The high dynamics and precision of each new pilot valve deliver optimum control of the main spool, resulting in servo-class performance from the complete valve. The control behaviour of the valves ensures high stability in operation and easy, time-saving installation and set-up. Whether in the direct or pilot-operated valves, the VCD technology offers the same benefits of robust design and long life.
A new safety concept with the pilot valve can also reduce the need for additional shut-off valves in hydraulics systems. It ensures the main stage is hydraulically balanced at power down and the main spool is in a safe position. The D*1FP range is available in four sizes: NG10 (CETOP05), NG16 (CETOP07), NG25 (CETOP08) and NG32 (CETOP10). With flow rates of up to 3000 litres a minute, the valves bring the advantages of VCD technology to almost any size of hydraulics system and are supported around the world by Parker's global network of manufacturing, sales and customer-support centres.
Source: ManufacturingTalk
March '09The new T7EEC pump offer high pressure ratings of up to 275 bar and total displacement of up to 554ml/rev. The low-noise pumps incorporate a single-piece shaft, enabling them to transmit internally cumulative torque without any restrictions for maximum operational efficiency.
As with all Parker multi-stage vane pumps, the new triple pumps feature a single suction port, allowing fast and simple connection to external piping. The innovative pump design also allows greater flexibility in positioning of both suction pipe and pressure ports, with 90° intervals to make installation simple where space is limited. The broad selection of displacements allows for up to 1,200 possible configurations, all with the same external pump dimensions.
The new pump is able to accommodate a wide range of hydraulic oil viscosities, permitting colder starts and hotter running, while the carefully balanced design of internal components automatically compensates for factors such as wear and temperature changes. In addition, at high viscosities or cold temperatures, the internal configuration of each pump ensures that crucial areas such as the gap between rotor and side plates remains fully lubricated at all times to enhance performance and operating life still further.
This new hydraulic vane pump has been developed for a wide range of applications, with is unique power to weight ratio (lightweight and compact design) making it ideal for use in industrial and marine market sectors.
Parker vane pumps are fully supported by the company’s worldwide network of manufacturing and customer support centres, with local technical knowledge and spare parts being readily available.
Source: Engineering Specifier
February '09
The Steam-Assisted Gravity Drainage (SAGD) trial was conducted in Canada by a major oil company.
The PCM Vulcain was installed in May 2007 and has been running non-stop ever since.
It is being used to pump bitumen so viscous that it will not slide out of an upturned cup.
It was installed as part of a trial to find a suitable replacement for electric submersible pumps that were underperforming due to the extreme pumping conditions.
After 20 months of operation, the PCM Vulcain has a 53 per cent volumetric efficiency at 390rpm.
In this trial, there are nine PCM Vulcains to date having already exceeded the 12-month mark.
The PCM Vulcain was developed through joint research and development conducted by PCM and major oil companies.
Source: Engineering Talk
January '09
These tools can be supplied to suit different thread forms, such as Williams and Dyson threaded bars and ISO metric and Imperial Unified Thread forms.
Other features include the gear nut run-down mechanism, which offers a rapid and consistent method to seat the foundation hexagon nuts during the tensioning procedure.
The Model WTF is then automatically ready to tension the next bolt.
This speeds up turbine construction.
Source: Engineering Talk
MDA India (Bangalore): 10th - 13th December
BFPA organise a group stand within the Fluid Power Pavilion. UKTI Support at Exhibitions
BFPA is a recognised UK Trade & Investment Group Organiser for specific exhibitions and limited grants are available to qualifying companies.
UK Exhibitions
2009 SED, Rockingham, Northamptonshire
12th - 14th May SeaWork, Southampton July '08
Upcoming Hydraulic Exhibitions:
BFPA organise a group stand in the Power Transmission Control section
PTC Asia (Shanghai, China): 27th - 30th October
In the renewable energies sector, Hagglunds Drives products are used to drive machines for producing ethanol and feature in the first prototypes for generating tidal energy. Bosch Rexroth plans to acquire all shares in Hagglunds Drives, which is based in Mellansel, Sweden The contract was signed on 18th July, 2008 in Stockholm, Sweden. This article was originally published on Engineeringtalk on 3 Jul 2008 at 8.00am (UK)
Bosch Rexroth plans to acquire all shares in Hagglunds Drives, which is based in Mellansel, Sweden The contract was signed on 18th July, 2008 in Stockholm, Sweden
The acquisition is subject to approval by the authorities.
In 2007, Hagglunds Drives employed around 900 people and achieved sales of approximately Eur 200 million.
Hagglunds Drives is a international supplier of complete hydraulic drive systems, separate drive motors and services.
The group develops, manufactures, markets and services complete drive system solutions for applications requiring high torque and variable speeds.
The drive systems are used in a wide range of industries, such as mining and materials handling, marine and offshore, recycling, sugar, pulp and paper.
In the renewable energies sector, Hagglunds Drives products are used to drive machines for producing ethanol and feature in the first prototypes for generating tidal energy.
"The acquisition of Hagglunds Drives expands our industrial hydraulics portfolio and by this we gain new potential in growing markets, such as renewable energies and mining and materials handling", according to Dr Albert Hieronimus, Chairman of the Executive Board of Bosch Rexroth.
Bosch Rexroth already offers a broad range of hydraulics solutions for industrial and mobile applications.
At present, however, it only supplies radial piston motors - the primary product manufactured by Hagglunds Drives - in performance classes for use in mobile applications, such as small construction machinery.
The headquarters of Hagglunds Drives in the Swedish city of Mellansel is also the company's largest production site.
Other production sites are located in San Antonio, Texas and Columbus, Ohio in the USA.
The hydraulics specialist has a global sales network and offices in over 20 countries, in addition to around 50 sales and service offices.
Source: http://www.engineeringtalk.com/news/mae/mae136.html
The inquest was adjourned to a future date to be fixed. The case is being investigated by the Health and Safety Executive.
The inquest at Norwich heard that Mr Henderson was using a mini-welding or cutting set and a joint separated under pressure and struck him in the face.
Robert Henderson, 49, of South Road, Beccles, Suffolk, was trying to transfer oxygen from one cylinder to another at a farm in Stockton, Norfolk.
A worker on a farm was killed when he was struck in the face by a hydraulic hose, an inquest has been told.
August '08
16th - 18th June Please contact BFPA on 01608 647900 for further information on exhibitions
Hannover Messe (Germany): 20th - 24th April
2009
FPA organise a group stand within the Motion, Drive & Automation Section
2008
Forthcoming overseas exhibitions:
BFPA arranges group stands or information booths at a number of overseas exhibitions, including IFPE (USA); PTC Asia (China) and the Hannover Fair (Germany).
Worldwide Hydraulics Exhibitions
November '08
Diffuser posts are interchangeable, and come with a male thread ranging from 0.5in NPT to 1in NPT.
The complete diffuser post can be removed from the vapour guard, cleaned, and then reinstalled.
Here the mist can condense back into liquid oil.
As this condensate builds, the liquid oil runs down the walls of the containment chamber and collects at the bottom.
The accumulated oil is channelled back into the bearing housing through bleed-back holes located at the bottom of the diffuser post.
The escaping mist enters the vapour guard through the diffuser post, and is dispersed inside the containment chamber.
A central diffuser post inside a sealed aluminium containment chamber is vented to atmosphere by a female port on top.
The Oilmiser vapour guard is threaded into the gearbox vent port and a clean air filter is threaded into the vapour guard.
With increasing heat and thermal expansion, oil vapours can form inside a bearing housing or gearbox and migrate up and out of the air vent.
JLM has released the Oilmiser vapor guard and the Oilmiser reservoir aspirator to prevent the loss of oil from machinery.
All suitable hoses and connections are available from Tentec.
For added versatility, multiple Aero WTF tensioners can be linked together with high pressure flexible link hoses to give simultaneous bolt loading.
WTF is also designed for nuts that use washers to DIN 6916 and DIN 125.
All Aero WTF tensioners have been designed for use with Structural Hexagon Nuts to DIN 6915 and more conventional nuts to DIN 934. No operator intervention is required.
This reaches down inside the tensioner to grip on to the short stud protrusion.
When there is long stud protrusion from the foundation hexagon nut, a spare nut can be used on top of the Aero WTF tensioner, whereas with a short stud protrusion, an extended length puller can be used.
As the amount of thread protruding can vary between turbines, the tensioning tool has been designed to work in two different ways.
Tentec has brought out the Aero Model WTF range of hydraulic bolt tensioning tools for wind turbines, with 25mm piston/ram capability for one-pull uninterrupted tensioning.
November '08
Source: EngineerLive
Breather caps for hydraulic systems
Elesa’s SMN and SMW breather caps for pressurised tank systems offer single and double valve operation. This smooths pressure fluctuations in the hydraulic fluid reservoir as oil is rapidly drawn out or returned to the tank.
A simple open vent would allow ingress of contaminants as well as outflow or spillage. So the SMN/W breather caps not only manage the pressure change, they also filter air flow and seal the tank so enabling the hydraulic pump itself to operate at its optimum by reducing fluid foaming and pump cavitation.
SMN/W breathers feature rugged chrome plated steel caps containing the necessary filtering and valving – they are also available as /BA bayonet fixing variants for even quicker usage.
Further more information, visit www.elesa.co.uk
A simple open vent would allow ingress of contaminants as well as outflow or spillage. So the SMN/W breather caps not only manage the pressure change, they also filter air flow and seal the tank so enabling the hydraulic pump itself to operate at its optimum by reducing fluid foaming and pump cavitation.
SMN/W breathers feature rugged chrome plated steel caps containing the necessary filtering and valving – they are also available as /BA bayonet fixing variants for even quicker usage.
Further more information, visit www.elesa.co.uk
December '08
Hydraulic Clamping Systems
The Hilma Automation AS 125 H Sensor from Roemheld makes clamping and operational errors a thing of the past. It automates setting up processes removing the need to manually adjust hydraulic clamping systems. As well as a position sensor, workpiece dimensions can be entered into a control system, recorded and then implemented. The sensor also enables one clamping system to cover large and small clamping widths as workpiece dimensions can be varied without the need to change the jaws.
Hebble Hydraulics successfully recertified one of the largest accumulators we have ever worked on. The client was ACC Plastics Group, who are a specialist plastic injection moulding company based in Rotherham. ACC Plastics Group are a well established company who are continually growing and they chose Hebble to complete the project. They decided to go with us as we are one of the only specialist companies that can offer recertification of piston accumulators and offer written scheme approval for pressure systems.
Hebble Hydraulics Complete Successful Recertification of Piston Accumuator for ACC Plastics Group
PCM has announced that its PCM Vulcain all-metal progressing cavity pump has pumped extremely hot and viscous bitumen for more than 20 months in a SAGD trial.
Parker Hannifin has added a new triple vane hydraulic pump to its extensive range of hydraulic equipment. Designed to offer high performance and long, low maintenance service life the new pump is particularly suitable for use in industrial applications and other environments where space is limited.
They are used on all kinds of deck equipment, winches, carousels, mud pumps, drilling equipment, cutterheads and tidal and wind energy projects.
Hagglunds motors are manufactured in Sweden to ISO9001 and environmental standard ISO14001.
With flexible hoses connecting the motor, it is also possible for the drive to move during operations so opening the possibility for the propeller to slew or move up and down with the close coupled drive. This technique is already used, for example, on Dredging cutterhead drives.
The high torque from the motors is available irrespective of the speed, so high starting torque is a standard feature. It may also be possible to improve propeller design to take advantage of this feature to operate at lower speeds and therefore lower noise levels. The company said that the drive arrangement is simple and installation is easy.
Hagglunds motors offer almost negligible inertia, which brings a response to the drive to give fast stopping in emergencies or for starting and stopping frequently with controlled ramp up and down times.
The motors and pumps are available on short lead times and Hagglunds has a worldwide network of sales and service facilities to offer support.
The mechanical efficiency of these motors is approaching 98 per cent, similar to that of a roller bearing.
The motors provide high torque without the need of speed reduction units.
They are also quiet compared to mechanical drives because there are no high-speed elements involved as gearboxes are eliminated.
The hydraulic motors can even be used in submerged conditions and are maintenance free, providing long and reliable life.
If the pumps used are variable displacement, the speed can be controlled independently of the engine, which would run efficiently at a fixed speed and with two propellers.
This provides the opportunity to look at the basic vessel design and make improvements based on the flexibility of major components, for example, to improve the weight distribution. It also means that all or some of the power can be diverted from the propulsion to other vessel requirements such as deck equipment when the full power of propulsion is not needed. More than one engine offers possibilities for redundancy and therefore extra security if needed.
Therefore, all the engineering involved in designing and installing the long prop shaft and the cost of the shaft and bearings are eliminated. This also frees up possibilities of positioning the engine and propellers anywhere in the vessel. Hydraulically, a number of propellers can be powered from the engine. Two or more engines can be used and the power can be shared between the drives.
These motors could provide benefits on propulsion systems on small to medium-sized vessels. For example, the propeller would no longer have to be mechanically connected to the engine with a long rotating shaft. It would be replaced with hydraulic pumps and just three hydraulic lines to the motor.
CBP motors from Hagglunds offer a speed range up to 320rpm dependent on the specific displacement, plus various sizes to choose from to suit the application.
LKAB 1.8 km overland belt conveyor Lulea Sweden.
Belt conveyors are employed to move bulk materials economically and efficiently saving costs of truck haulage which can often have detrimental effects on the environment and local road infrastructure. This belt conveyor for small round pellets goes up and down hill with frequent starts and stops so a drive with very smooth speed control is essential to prevent the pellets slipping or running on the belt. The Hagglunds drive provides this with full torque available throughout the speed range so you can adjust the speed without concern about torque and the ramps are smoothly controlled within the Hagglunds control system.
Internal rubber mixer
Internal rubber mixers are very intensive batch process machines with heavy duty requirements since solid rubber is fed into the machine with various other ingredients to mix together into various compounds for tyres and seals etc The Hagglunds solution enables variable speed ratio between the rotors on tangential machines so the speeds can be adjusted to suit the compounds being produced.
The Gemini system loses non of the attractive features of typical Hagglunds drive systems with infinitely variable speed, the unbeatable power to weight ratio giving very compact space saving dimensions around the driven shaft area and very low inertia which means a very responsive drive to accelerate or decelerate, one that can stop very quickly if overloaded so preventing catastrophic failure of machine components because the torque absorbed is always kept under known limits by the fast acting pressure controls in the swash plate pump. If the drive is overloaded it will simply stall and hold the controlled torque so protecting the machine from unacceptable forces which with geared drives with massive inertia’s in comparison can cause expensive damage and plant downtime.
Other applications are large overland conveyors, ship propulsion and process applications like chemical reactors and internal mixers.
With such high powers now available applications such as renewable energy applications like wind and tidal can utilize these big motors to act as pumps to supply large axial piston motors driving generators.
• The power unit, which can comprise of several motor pump units.
• The tank unit, which supplies the hydraulic fluid and keeps it cool. It also has system monitoring with local controls and displays.
• The Service unit houses the filtration system where most of the routine maintenance occurs.
• The control unit is PLC based and controls the whole system using BUS technology with health monitoring and logging information for analysis.
• Piping and hosing is prefabricated flanged non welded of highest quality.
To accommodate these high powers Hagglunds have developed a modular power unit system called Gemini. The system comprises the following modules –
To achieve 6000 lt/min flow you need 8 large pumps with a displacement of 500 cc/rev operating at 4 pole speed of 1475rpm. This is quite a formidable power unit.
This means that Hagglunds can now offer drive motors that can give a continuous power output of over one thousand KW or over one MW and still retain the favourable smooth reliable torque characteristics the Hagglunds have been know for, for many years. The motors have a maximum continuous pressure of 350 bar but normally the motors are sized for working pressures around 200 bar so this means that for the full power for just one motor, a flow of around 3000 lt/min is needed from the power unit. Obviously for a machine with two drives motors such as a typical twin rotor internal rubber mixer the flow would be double this.
More recent developments at Hagglunds has now produced motors that can even push the boundaries of conventional hydraulic drive engineering. The new CBP motors can operate at very high power due to the additional port plate designed into the motor enabling twice the flow capacity that was available before. Since power equals torque multiplied by the speed, by doubling the speed, the output power is also doubled whilst keeping the overall efficiency at very high levels. Such performance requires attention to other areas to achieve high integrity and reliability such as the shaft sealings and much testing has been going on in Hagglunds large laboratories in Sweden for the last few years. Indeed so much power to test is now needed for these high power CBP motors that new cooling systems taking water from a large nearby lake have been installed to cater for the high power testing needed. Don’t worry environmentally, the temperature of the lake has been calculated and the temperature rise will be insignificant to local fauna and flora.
The drive motors can produce very high torque from starting and throughout the speed range and so for example, starting a conveyor under full load is no problem. It can also be inched forwards and backwards, stopped and started as often as you like without limits because the control of direction and oil flow is achieved by the variable displacement pump alone, the AC electric motor runs efficiently at constant speed. The only need to stop the electric motor is when shutting down for lengthy periods. This opens up a new world of control on large machines.
Hagglunds pushes the boundaries of hydraulic engineering
Hagglunds have long been known for producing large hydraulic motors, so large in fact that they can replace large gearboxes completely thereby offering a direct hydraulic drive to applications like conveyors, shredders, drums and winches. This enables the inherent benefits of hydraulics to be used for the first time in very large drive applications producing significant performance improvements.
