IFPE’s continuing education courses offer hands-on technical knowledge in hydraulics and pneumatics technologies. These half-day courses will benefit practicing engineers and others involved in design and manufacturing practices. Registration for each course is $300, or $225 per course if registering for two or more. Certificates for PDH or CEUs are available upon completion of each course.

Click here to register.

Monday, March 3

8:00 to 12:00 — Overview of Fluid Power Systems
Gain a thorough understanding of the fundamentals of a hydraulic system’s construction in comparison to other drive and control systems. A summary will be provided of the main components that make up a hydraulic system and how to read schematics. The presentation will close with discussion of hydraulic circuits for basic applications.
Presented by Medhat Khalil, Director of Professional Education, Milwaukee School of Engineering

1:00 to  4:00 — Sizing a Hydrostatic Transmission Using Calculations
Learn two methods of calculations used to properly size and select the pump and motor for a closed circuit transmission application. The first method is to calculate the “Power Range” of your vehicle or machine; this method is used when the final gear reduction between the motor and load is unknown or the customer wants assistance to select the final drive ratio. The second method is used when the final drive ratio is specified by the customer.
Common vehicle and machine performance requirements that will be calculated include:
• Tractive effort and vehicle speed in the normal working range.
• Drawbar pull and vehicle speed in the normal working range.
• Gradeability and vehicle speed in the normal working range.
Presented by Tom Blansett, Manager, Training Services, Eaton Corp.

Tuesday, March 4

8:00 to 12:00 — Condition Monitoring for Hydraulic Fluids
Learn the basic concepts related to operating and maintaining real-world hydraulic systems through proper fluid selection and condition monitoring techniques. The course is divided in three parts: STLE overview, oil analysis (basics of oil analysis and justification for an oil analysis program), and hydraulic fluid selection.
Presented by James Hannon, ExxonMobil, and Dr. Robert M. Gresham, Society of Tribologists and Lubrication Engineeers

1:00 to 4:00 — Design, Modeling and Control of Hybrid Powertrain
With the rising oil demand and concerns on climate change, improving fuel efficiency and reducing emissions has become the main target of powertrain research for both on-road vehicles and off-road machineries. Powertrain hybridization has been widely accepted as one of the most promising solutions for addressing this issue. In a hybrid powertrain, an alternative power source (electric power or fluid power, for example) complements the internal combustion engine, to improve fuel efficiency by engine downsizing, load leveling, and regenerative braking. This short course will cover the background information, the various types of hybrid powertrain systems, different hybrid architectures, and the modeling and control of the hybrid powertrain.
Presented by Zongxuan Sun, Department of Mechanical Engineering, University of Minnesota

Reducing energy consumption is a priority in most every manufacturing plant and industrial facility, as no company can afford to throw money away using machines and processes that waste energy. Because pneumatic systems are ubiquitous throughout manufacturing and can account for a large share of a plant’s power costs, it is extremely important that they run efficiently.

Unfortunately, many users have the mindset that pneumatic systems are inherently inefficient, and so overlook opportunities for energy savings. In addition, some manufacturers of industrial equipment and robots tend to focus on ensuring the pneumatic systems perform their intended functions, and in the process neglect efforts to reduce operating costs. These OEMS instead should instead recognize that plant operators are becoming more concerned with total cost of ownership (TCO), of which energy cost is a major component. These customers know that energy usage can account for up to 75% of machine and robot TCO, and they’re looking to suppliers to help them reduce that bill.

The old business model of only caring about performance and not about efficiency is dying. In the long run, OEMs that include energy efficiency as part of the overall performance of their pneumatic systems will be better positioned to succeed than those that neglect TCO.

Fortunately, both OEMs and users can improve the energy efficiency of pneumatic systems, with tactics that range from better engineering decisions in the design stage to adjustments and maintenance on existing systems.

Start with compressors

According to data from the U.S. Department of Energy, manufacturers spend more than $5 billion each year on energy for compressed-air systems. By optimizing these systems, companies can reduce their compressed-air energy consumption by anywhere from 20% to 35%. The DOE offers guidelines for determining the cost of compressed air in a plant, as well as tips on how to reduce compressor energy consumption. Visit the site for more information.

Right-size components  

Correctly sizing pneumatic-system components helps cut costs in several ways, as each component can affect other parts of the system. For example, undersized control valves may initially be cheaper than larger, right-sized units, but they require the air compressor to work harder to get the proper pressure to the actuators.

On the other hand, while some oversizing is necessary to compensate for pressure fluctuations and air losses, grossly oversized components account for one of the biggest energy drains in a pneumatic system. If an engineer simply oversizes from a 2-in. to a 3-in. cylinder, for example,  required air volume will more than double. Correctly sizing a cylinder can reduce its air consumption by at least 15%, which becomes even more significant in systems with many cylinders that cycle thousands of times over their operating life.

In general, most loads and speeds require only 25% additional capacity to ensure proper operation. While many calculations and considerations go into right-sizing componentssuch as whether a load is rolled or lifted‑software packages, online calculators, and even iPhone apps can assist with computations. By spending a little more time in the design phase, OEMs can deliver substantial energy savings to their customers.

Right-sizing pneumatic components will not only increase customer satisfaction, it lets OEMs cut their own expenses. Larger and heavier components use more energy and create a larger footprint, which no manufacturer likes, and they cost more up front.

Optimizing pressure

As compressed air flows through typical circuits, air pressure drops due to changes in demand, line and valve flow resistance, and other factors. But many of these losses are simply because the distance between the compressor or supply point and the actuator is longer than necessary.

Designs that use the shortest tubing possible can reduce energy consumption as well as cycle times. Typically, tubing between control valves and cylinders should be less than 10 feet long. Longer lengths require more pressure so that force, speed, and positioning capabilities aren’t compromised.

Another way to eliminate unnecessary consumption is ensuring actuators use only the pressure needed to perform a task. Sometimes, operators on the plant floor increase supply pressure in the belief that it improves performance. However, all this does is waste energy and money. Installing sensors that monitor pressure, and pressure regulators that maintain correct settings, can keep pressure within the minimum and maximum parameters.

Many engineers also design systems that deliver more pressure than needed to the actuator. Regulators that control pressure to individual pneumatic cylinders will increase energy efficiency, in many instances generating savings of up to 40%.

The same holds for complete machines. OEMs typically design standard equipment to accommodate users who need the highest forces. Adding pressure regulators lets OEMs more accurately size components while still meeting a range of performance requirements.

Don’t overlook the return stroke

Another way to conserve energy is by supplying the correct pressure for an actuator’s return stroke. Most applications only move a load in one direction. However, many machines use the same pressure for both the working and return strokes.  

For example, a material-handling system that pushes boxes from one conveyor to another needs high cylinder force only in one direction. The working stroke may demand 100 psi to move a box, but the low-force return stroke only requires 10 psi. Using the same pressure in both directions wastes energy. Reducing the pressure on the return stroke saves 90% percent of the volume of compressed air. Because that conserves compressed air, a lot of energy is saved over the thousands of cycles that the action is performed. 

Another important and often overlooked benefit of regulating air pressure to the minimum required level: It lessens wear and tear on the pneumatic and related components. Not overpressurizing the retract stroke reduces vibrations and shock to the machine. Moreover, adding a quick-exhaust valve can reduce cycle times because exhaust rate on the return stroke affects cylinder speed.

Processes with shorter strokes can use single-acting, spring-return cylinders. A control valve ports compressed air to the cylinder for the working part of the stroke, and then exhausts that air. During the return stroke the spring, or sometimes merely the weight of a mechanism, brings the cylinder back to the starting position.

A typical case where single-acting, spring-return cylinders can reduce energy demand involves presses. In this type of application, a cylinder pushes two items together‑such as a bearing into a housing, or a plug into a hole. The job demands a significant amount of force to press the parts together, but only a small amount to retract. This makes it a good candidate for energy savings by minimizing return-stroke air consumption.

Turn it off

Shutting down a machine when it’s not working seems like an obvious way to save energy. While some elements of a system, such as air bearings, can require pressure even when the machine is off, the required compressed airflow is usually much less than that needed during normal operations.

However, many installations have no automatic way to reduce or stop airflow to idle machines. Reduced staffing often means that manufacturers can no longer send maintenance workers to manually turn off air to specific machines. In these instances, automatic air-reduction controls will lower air pressure or, if appropriate, shut it off completely when the machine isn’t working, more than paying for itself in short order.

Minimize leaks

Leaks are common and expensive in pneumatics systems. Statistics from the U.S. Department of Energy show the average manufacturing plant loses 30% to 35% of its compressed air due to leakage. The good news is many leaks can be prevented or repaired.

There are many points between the compressor and the load where leaks can be fixed, with valves and seals two main areas for improvement. Deteriorated seals and certain valve designs, such as lapped-spool valves with metal seals, have inherent internal leakage that is constant as long as air is supplied to the valve. Switching to valves with soft seals can significantly lower this leakage.

However, it’s important to note that air consumption in lapped-spool and metal-sleeve valves doesn’t vary during operation. On the other hand, during an open crossover when the valve shifts, a soft seal produces hundreds of times more leakage than a lapped spool-and-sleeve valve. Therefore, selecting the right type of valve for an application can minimize air leakage.

It’s equally important to consider environmental conditions such as temperature and humidity, and type or lack of lubrication, as these all affect the leakage rate of a seal. In some instances, hardy and relatively expensive seals like Viton, Teflon, or polyurethane may be the best option.

Systems approach

Pneumatic systems aren’t quite as simple as they might first appear. The engineering concept of actuating valves and moving loads with air is quite straightforward, but optimizing pneumatic system designs and maintenance involves many variables.

Perhaps the complexity of operating conditions and component selection is a large factor in the general inefficiency of these circuits, but pneumatic systems can be greatly improved by implementing the concepts discussed here.

OEMs play a big part because much of the energy inefficiency of pneumatic systems can be remedied at the design level. Machine users also have a crucial role to play as they are responsible for the overall operation and maintenance of a plant’s pneumatic system.

Perhaps in the past it was acceptable to build systems that worked well but wasted large amounts of energy. However, in today’s world, users are more aware of how energy consumption affects their bottom line. As such, OEMs must consider their customers’ TCO, not just upfront costs.

Pat Phillips is Product Manager in the Fluid Power and Mechanical Products Division at AutomationDirect, Cumming, Ga.

The Dakar off-road international race is made up of two marathon stages that stretch across miles of South America’s desert terrain. This year, the Chevy Colorado Z71 Rally Raid prototype vehicle will feature HAWE hydraulic valves to help withstand the tough conditions.

The major sporting event not only challenges its drivers’ endurance and racing skills, but their strategic navigational competencies through the terrain. Separated into four classes—bike, quad, car, and truck—each vehicle has to be specially souped up to withstand the wear and tear of the harsh environment.

Chevy chose HAWE’s directional spool SG 1L – AKS valves for use on the 2014 Rally Raid prototype. Available in SG (pipe connection) and SP (manifold mount) versions, the valves allow up to 400 bar, 100 lpm and help control the oil flow and directional movements of jacks within the vehicle. The system’s entirely steel design is resistant to pressure surges and leaks, eliminating the chance of hairline cracks and other damage that can be caused by the desert conditions. The valves have either positive (blocked between switching positions) or negative (slightly floating position) overlap. Other applications include mining machinery, cranes and lifting equipment, and shipbuilding.

Starting on January 5^th, 2014, the race will continue until the 18^th, covering a total of 2,702 km (and 1,590 km of special stages) over three countries (Argentina, Bolivia, and Chile). Inaugurated in 1979, the Dakar rally now hosts over 500 riders a year from countries all over the world.

For a closer look at the Dakar click here.

More information about the race can be found here.

In addition to the IFPE Technical Conference and college-level short courses, IFPE will also host a series of free seminars. Sessions consist of generic topics presented by professional trainers and industry experts. Seminar sessions are arranged in convenient 1-hr intervals, so participants can attend at their convenience. All sessions are free to anyone registered for ConExpo/ConAgg and IFPE 2014, all you will need to attend is your show badge.

Sessions will be held throughout the day on Wednesday, March 5 and Thursday, March 6. Attendance is free to anyone registered for ConExpo/ConAgg or IFPE 2014.

Wednesday, March 5, 2014

Morning Session: Best Practices in Mobile Hydraulic Maintenance
Mobile hydraulic systems are powerful, so it’s important to practice safety when maintaining them. This session covers money-saving maintenance techniques for hydraulic systems and how to work safely around them.
Presented by Robert J. Sheaf Jr., CFC Industrial Training.

Morning Session: Reducing Leakage and its Environmental Impact

Hydraulic fluid leaks are not only messy, but unsafe and can cost your company plenty if they harm the environment. This session examines practical techniques to eliminate, reduce, and manage leaks.
Presented by Robert J. Sheaf Jr., CFC Industrial Training.

Afternoon Session: Pneumatic Systems in Mobile Equipment
Pneumatic systems are widely used in all types mobile equipment, so this session explores important issues of mobile pneumatic systems that often are overlooked that those familiar with industrial pneumatics.
Speaker to be determined

Morning Session: Balancing High-Strength Tubing Selection and Cost in Hydraulic System Design
Hydraulic system engineers who need metal tubing to meet today's demands for higher system pressure are often faced with limited choices and cost constraints.  This session will explore high-strength tubing options and their impact on system design and how new developments in high-strength tubing give designers more cost-effective solutions.
Presented by John H. Wilbanks, Quality Manager, Plymouth Tube Co.

Afternoon Session: Contamination Management in Hydraulic Systems
By far, hydraulic fluid contamination is biggest cause of hydraulic system malfunctions. This session helps attendees reduce operating costs and downtime through contamination assessment and control.
Speaker to be determined.

Thursday, March 6, 2014

Morning Session: Understanding Mobile Hydraulics
This session provides an overview of the wide variety of pumps, valves, and controls used in mobile hydraulic systems to make mobile equipment more efficient, powerful, and versatile than ever.
Presented by Terry Hershberger, Bosch Rexroth Corp.

Morning Session: Electronic Control of Mobile Hydraulics
Picking up where the previous session leaves off, this presentation summarizes electronic pump and valve controls and their advantages over conventional pilot-operated systems in mobile hydraulics.
Presented by Terry Hershberger, Bosch Rexroth Corp.

Afternoon Session: Troubleshooting Excavators and Loader Backhoes
After providing an overview of hydrostatic transmissions and other circuits commonly found in mobile equipment, this session examines basic malfunctions that occur and how to identify and correct them.
Presented by Robert J. Sheaf Jr., CFC Industrial Training.

Afternoon Session 2D: Troubleshooting Hydraulics in Aerial Lifts
This session opens by reviewing common circuits used in mobile lift equipment, common malfunctions that occur in lift circuits and drives, and how to pinpoint their causes and correct them.
Presented by Robert J. Sheaf Jr., CFC Industrial Training.

Note: These sessions assume the attendee has a basic knowledge of fluid power systems. To gain a working knowledge of hydraulic and pneumatic systems, please refer to the short course, “Overview of Fluid Power Systems,” which is being held Monday, March 3 in the South Hall.

The Enrange CHTX wireless control for mobile hydraulic machines has a large control area to handle a variety of joysticks, toggle switches, key switches, and selector switches. The customizable transmitter is IP65 rated, sealed to withstand harsh environments, and minimizes power consumption. It easily combines with MHR, CAN-2, CAN-6, and Flex M receivers. It can also serve as a replacement for pedestal-mounted controls.

Magnetek Enrange, (800) 288-8178

Pyplok mechanically attached connectors reduce assembly time by swaging it on a pipe or tube with a hydraulic handheld tool. Its three-step cold installation process is simple after cutting and deburring the tube or pipe.Features include: No skilled labor required; installation time measured in seconds; no welding; and no leaks.

The connectors are for use with ¼ to 2-in. OD tube, 6 to 90-mm metric tube, and ¼ to 3-in. NPS pipe. Pyplok is dependent on OD; the wall can be any thickness. The connectors handle pressures to 10,000 psi.

Tube-mac Industries Inc., (888) 285-9243

The new HPP (High-pressure piston) range of leak-free pneumatic regulators is designed for instrument and industrial control applications. The regulator’s piston design manages supply pressures up to 6,000 psi at temperatures up to 260°C and delivers pressures between 3,000 and 1,000 psi.

The HPP is constructed of 316 stainless steel and feature improved valve seat sealing to eliminate the risk of media leakage associated with conventional high-pressure regulators.

The units are available with 6-mm (¼-in.) ports in either two or four- port configurations and in multiple output pressure ranges. Standard knobs can be replaced with tamperproof caps for high-temperature and/or nonadjustment applications.

The regulators mount at the ports, the bottom surface, or in panel-mounted configurations.

Rotork Fairchild, (800) 334-8422

The high-pressure V080 and V130 Series of mobile hydraulic directional-control valves can be configured with a full array of spool, control, and positioner options. Designed for flows to 60 gpm, the valves can be configured with custom options.

Muncie Power Products Inc., (800) 367-7867

The V60N-130 axial piston pump offers standard torque limitation for a vehicle’s gearbox. Other features include up to 130 cm³/rev displacement and 450-bar peak pressure. The pump is suitable for load-sensing systems working at operating pressures of up to 400 bar and supplying hydraulic consumers with different pressure requirements and variable flows. With the pump flanged directly to the power take-off of a vehicle’s gearbox, engine power is transmitted directly to the pump without losing energy unnecessarily. Alternatively, with SAE- and ISO-standardized flanges, the pump can also be connected to separate transmissions. A through-shaft allows installing an additional pump for ancillary functions. It easily withstands peak pressures to 450 bar.

Hawe Hydraulics, (980) 207-5642

IFPE 2014 will be the place to be to learn about all things fluid power. As in they have since 2002, IFPE and ConExpo will be held simultaneously at the Las Vegas Convention Center. This year’s Conference is scheduled for Tuesday, March 4 through Saturday, March 8, with the IFPE Technical Conference running Wednesday, March 5 through Friday, March 7. Specifically, conference sessions will be held in the South Hall Bridge Meeting Complex. In addition, four-hour short courses will be conducted Tuesday, March 4, and a series of free fluid power seminars will be conducted Wednesday and Thursday, March 5 and 6. The IFPE Technical Conference will emphasize new technologies and methods related to improved analysis, design, manufacture, and performance of fluid power components and systems.

Registration for the IFPE Technical Conference is $85, which includes admission to all technical presentations, two keynote presentations, a flash drive with the Conference, and a certificate for PDH or CEUs.

Wednesday, March 5

W1 Modeling: Hybrid (Green), PCB Stability, Controls | 8:45 am - 10:15 am

Using Simulation to Create Real Efficiency in Hydraulic Control Systems
David Ruxton, Applications Engineer, HydraForce and Nick Stabile, Design Engineer Group Leader, HydraForce

W2 Wireless Technology: Applications, Performance, Safety | 8:45 am - 10:15 am

Machine Control with Only Two Hoses
Douglas Anderson, Systems and Application Engineer, Danfoss

W3 Controls: Analysis, Performance, Systems | 8:45 am - 10:15 am

Servo Motion Control with Custom Feedback Increases Operation Uptime, Reduces Maintenance, and Improves Monitoring of Machine Parameters
Peter Nachtwey, President, Delta Computer Systems Inc.

Practical Solutions for Open Circuit System Instability
Chad Daniel, Manager, BA Sales Americas, Danfoss

Hydraulic “Jerk” on Articulated Vehicles
Jared Cave, Systems and Applications Engineer, Danfoss

W4 Modeling Pumps for Design and Performance | 10:30 am - 12:00 pm

Comparison of Steady State Flow Loss Models for Axial Piston Pumps
Samuel Hall, System and Application Engineer, Danfoss

On the Hydraulic Pumps Modeling for Applications Engineers
Medhat Khalil, Director of Professional Education, Milwaukee School of Engineering

Mathematical Modeling and Experimental Research on Influence of Improved Stator Curve on the Characteristic of Vane Pump
Radovan Petrovic, Professor, College of Applied Engineering, Center for Power Control Hydraulics

W5 Noise Control: Modeling and In-Line Supression | 10:30 am - 12: 00 pm

Prediction of the Acoustic Radiation from a Hydraulic Piston
Michael Beyer, Senior Technical Specialist, Eaton Corp

Optimization of Dissimilarly-Sized Dual In-Line Suppressors
Elliott Gruber, Graduate Student, Georgia Institute of Technology

W6 Hydraulic Energy Storage Methods | 10:30 am - 12:00 pm

Fluid Power in Transportation
Charles Juhasz, Director of Engineering, Scientific Services Inc

Experimental Studies of Viscous Loss in a Hydraulic Flywheel Accumulator
Kyle Strohmaier, Master's Student, University of Minnesota

Industrial Application of an Intelligent and Efficient Fluid Power Storage System
Leonid Sheshin, Head of Fluid Power Department, Lumex-Marketing Ltd

Keynote Presentation

Energy Consumption in Fluid Power – The Impact and Potential Savings in Mobile Machine Applications  1:00 - 2:00 pm
Lonnie Love, PhD, Group leader of Oak Ridge National Laboratory's (ORNL) Automation, Robotics and Manufacturing Group
Fluid Power is a foundational technology for both the manufacture and operation of mobile machines. However, there are many areas where fluid power can improve. A recent ORNL/NFPA study suggests that between 2% and 3% of U.S. energy consumption is derived from fluid power components and systems. Furthermore, the average efficiency of fluid power systems is approximately 21%--although typically higher in mobile machines. Therefore, moderate improvements in efficiency can yield tremendous energy savings. Emerging trends in advanced manufacturing (additive processes, light weight metals, low cost carbon fiber) can simultaneously increase efficiency as well as improve competitiveness. Another challenge is workforce development. How can we inspire youth to not only consider careers in science and engineering, but become knowledgeable about the benefits and efficiency potential in fluid power?

W7 New Pump Designs (Digital/Discrete) and Applications | 2:15 - 3:45 pm

Midsize Wind Turbines with Hydraulic Transmissions
Feng Wang, PhD, University of Minnesota

Applications for Discrete Flow Pumps
Matt Kronlage, Product Applications Engineer, Turolla OpenCircuitGear

DHTM475- The Evolution of Flow
Elton Bishop, Manager, DigitalHydraulic LLC

W8 Using Hydraulics for Tier 4 Off Highway Compliance | 2:15 - 3:45 pm

Engine Overspeed Protection for Tier 4 Machines with Hydrostatic Transmissions
Simon Nielsen, Systems Engineer, Danfoss

Modern Hydrostatic Propel Drives Change Wheeled Off-Road Vehicles
Jӧrn Petersen, Sales Director Construction Machinery Sector, Bosch Rexroth

W9 Controls: Analysis, Performance, Systems | 2:15 - 3:45 pm

Coordinating Subsystem to Maximize Efficiency
Timothy Post, Application Engineering Manager, Hydro Electronic Devices

Hydraulic Generator Drive Robust Control
Christian Daley, Engineer, Danfoss

Pressure Control in Pulsed Electrohydraulic Forming of Sheet Metal
Celestine Okoye, University Lecturer, Federal Ministry of Education Headquarters

W10 Novel Methodology for Analysis of Pumps and Motors | 4:00 - 5:00 pm

Equations to Fluid Power Components
Nahum Goldenberg, CEO, HydroCAD-Nahum Goldenberg Ltd

A Novel Methodology of Displacement Calculation for the Swash Plate Axial Piston Pump with Conical Cylinder Block
Will Guo, Engineering Team Leader, Danfoss

W11 Pneumatics: Reusable Energy, Robotics, Orthotics | 4:00 - 5:00 pm

Heat and Efficiency Considerations in Fluid-Powered Co-Robotics Applications
Douglas Cook, Staff Researcher, Milwaukee School of Engineering

Walking Energy Hydraulic Regeneration Potential to Extend Range of Active Orthotic Exoskeletons
Keith Fisher, Associate Professor, Montana State University

W12 Work/Duty Cycles: Determination and Optimization | 4:00 - 5:00 pm

Establishing an Optimal Work Cycle for an Alternative Wheel Loader Concept
Bobbie Frank, Alternative Drivetrain Research Engineer, Volvo Construction Equipment and Lund University

Drive Cycle Formation Procedures for Off-Highway Vehicles
QingHui Yuan, Manager, Eaton Corp

Thursday, March 6

T1 Fluid Performance: Temperature, Film Thickness, Base Stock | 8:45 - 10:15 am

Study of Temperature and Lubricant Effects on the Efficiency of a Complete Hydrostatic Drive System
Shubhamita Basu, Technology Manager, The Lubrizol Corporation and Edward Akucewich, Technical Fellow, The Lubrizol Corp

Effect of Base Stock Type on Film Thickness and Performance in Hydraulic Pumps
Edward Akucewich, Technical Fellow, The Lubrizol Corp

Hydraulic Fluid Efficiency Effects in External Gear Pumps
Paul Michael, Research Chemist, Milwaukee School of Engineering

T2 Modeling: Vane Pumps and Valves | 8:45 - 10:15 am

A Numerical Model for the Simulation of Flow in Radial Piston Machines
Pulkit Agarwal, Graduate Student, Purdue University

New Non-Linear Model for a 4-Way Directional Control Servo or Proportional Valve
Jack Johnson, Electrohydraulic Engineer, IDAS Engineering Inc

A Non-Linear Valve Model is Applied to a Highly Overlapped Proportional Valve
Jack Johnson, Electrohydraulic Engineer, IDAS Engineering Inc

T3 Wireless Technology: Application, Performance, and Safety | 8:45 - 10:15 am

Connecting Your Vehicle to the World
Christopher Kolbe, Vice President of Sales & Marketing, Hydro Electronic Devices

Applying Wireless Technology to Electro-Hydraulics: Architecture, Compliance, and Safety Considerations
Anthony M. Di Tommaso, Manager, Product Development, Cervis Inc.

CAN Be Safe
Brian Spranger, Software Engineer, Danfoss

T4 Hydraulic Hybrids: Simulation, Design, Performance | 10:30 am - 12:00 pm

Control System Development for a Hydraulic Hybrid Lift Truck
Michael Olson, Lead Engineer - Controls and Modeling, Eaton Corp

Comparison of Two Different Electronic Feedback Methods to Increase the Damping in the Simulation Model of Electro-Hydraulic Hybrid Actuator System for Off-Highway Working Vehicles
Rafael Aman, Post-Doctoral Researcher, Lappeenranta University of Technology

T5 Valves: Modeling, Performance, Contamination | 10:30 am - 12:00 pm

Control and Stability Analysis of a Practical Load-Sense Systems
Abhijit Das, Advanced Systems Engineer, Danfoss

Improvements in Controllability and Efficiency of Electronically Controlled Valve Systems
Gary LaFayette, Sr Engineer, Danfoss

Servo Valve Design for Faster Response in motion Systems and Also Low Contamination Susceptibility
K. Osaka, Design Engineer, R&D Department, Yuken Kogyo Co

T6 Fluids: Environment, Performance (Including Hybrids) | 10:30 am - 12:00 pm

Environmental Lubricants in the Fluid Power Industry
Mark Miller, Executive Vice President, Terresolve Technologies/RSC Biosolutions

The Effects of Fluid Properties on the Efficiency of Hydraulic Hybrid Vehicles
Steven Herzog, OEM Liaison Manager, Evonik Oil Additives USA Inc.

Improving Fuel Efficiency, Productivity and GHG Emissions of Off-Highway Equipment Through the Use of Energy Efficient Hydraulic Fluids
Thomas Schimmel, Business Segment Manager, Hydraulic Fluids, Evonik Oil Additives USA Inc.

Keynote Presentation

Hydraulic Hybrid Excavator – Customers, Diversity Drives Innovation 1:00 - 2:00 pm
Ken Gray, Global Product Manager, Large Hydraulic Excavators, Caterpillar Inc.
The fuel-saving Cat® 336E H Hybrid was launched in 2013 as the industry's first hydraulic hybrid excavator. With over 300 patents filed, the innovative hydraulic hybrid technology is a significant departure from the typical hybrid approach. To accomplish such a feat required an acute, intense focus on the customer and a diverse, global team empowered to drive an innovative solution. Learn the story behind the development of this game-changing product from Caterpillar.

T7 Hydraulic Hybrids: Energy Recovery and Reuse | 2:15 - 3:45 pm

Towards a New Kind of Energy Recovery for Electric Vehicles
Jose Garcia, Assistant Professor, Purdue University

Hydraulic Hybrid System for Swing Energy Recovery and Reuse
Jiao Zhang, Engineering Technical Steward, Caterpillar Inc.

Series Hybrid Hydraulic System
James O'Brien II, President, NRG Dynamix

T8 Fluids: Filter Testing, Water Monitoring and Control | 2:15 - 3:45 pm

Got Water?
Jawad Khan, Data Analyst, Polaris Laboratories

Laboratory and Field Investigations of Water-Adsorbing Oil Filters and Relative Humidity Sensors
Paul Michael, Research Chemist, Milwaukee School of Engineering

Impact of the Use of Secondary Particle Counter Calibration Samples on Particle Count and Filter Test Results
Bryan Steffan, CV Test Engineer, Cummins Filtration Inc.

T9 Hydraulic Fan Drive Systems: Design and Performance | 2:15 - 3:45 pm

Improvements in Reversing Fan Drives
Stephen Frantz, Staff Engineer, Danfoss

Dedicated Closed Circuit Hydrostatic Fan Drive Control
Josh Cronbaugh, Product Engineer, Danfoss

Open Circuit Fan System Stability Analysis
Robert Harris, Systems and Application Engineer, Danfoss

T10 Valves: Adjustment, Modeling, Empirical Evaluation | 4:00 - 5:00 pm

Methods to Adjust the Characteristic Curves of Electro-Hydraulic Proportional Valves in Mobile Applications
Mark Jankowski, Engineering Manager, Thomas Magnete USA LLC

Empirical Method Produces Improved Consistency In Variable Discharge Coefficient Effects
Jack Johnson, Electrohydraulic Engineer, IDAS Engineering Inc

T11 Test Stands and Procedures: Digital Pumps/Motors, Air-Borne Noise | 4:00 - 5:00 pm

Meeting ISO3744 – Determination of Airborne Noise Generated by Hydrostatic Unit
Jaromir Tvaruzek, NVH Senior Engineer, Danfoss

Development of a Portable Pneumatic Educational Tool for STEM Education
Farid Breidi, Student, Purdue University

T12 Sensors: Thermal Properties and Pressure Ripple Energy for Sensing | 4:00 - 5:00 pm

Applications of Thermal Actuation Technologies within the Fluid Power Environment
Gary Swanson, President, Thermotion LLC

Pressure Ripple Energy Harvester Enabling Autonomous Sensing
Ellen Skow, Research Graduate Assistant, Georgia Institute of Technology

Friday, March 7

F1 Connectors, Manifolds, Cylinders | 8:45 - 10:15 am

Corrosion Protection Methods for Fluid Connectors
Josef Pfister, Division Engineering Manager, Parker Hannifin Corp

New Process for Improved Seamless Forged Pipes for Hydraulic Cylinders
Pierre Sutter, Product Manager, Vallourec

Pressure Ratings and Design Guidelines for Manifold Applications
Robert O’Rourke, Product Engineering Manager, Dura-Bar

F2 Pneumatics: Performance, Reusable Energy, Seal Friction | 8:45 - 10:15 am

Two-Phase Heat Regeneration in Hydraulic Accumulators: Efficiency Improvement at Low Cost
Alexander Stroganov, President, Lumex Instruments Canada

Characteristics of Air Flow Control Components for the Emergency Breathing System
So-Nam Yun, Valve Developer, Korea Institute of Machinery & Materials

Pneumatic Lipseal Friction
John Berninger, Consultant, Parker Hannifin Corp

F3 Air in Fluids: Effect and Elimination | 8:45 - 10:15 am

Air Bubble Separation and Elimination from Working Fluids for Performance Improvement of Hydraulic Systems
Yutaka Tanaka Sayako Sakama, Professor, Hosei Univeristy

Impact of Gas Cavitation in the Instantaneous Flow Provided by External Gear Pumps
Andrea Vacca, Assistant Professor, Maha Fluid Power Research Center, Purdue University

F4 Charge Pump, Reservoir Design, Seal Friction | 10:30 am - 12:00 pm

Mobile Equipment Reservoir Baffle Innovation
Robert Post, Contributing IFPS Member, on behalf of IFPS

Charge Pump and Loop Flush Sizinng for Closed Loop, One Pump, Multi-Motor Systems
Brent Sinclair, Systems and Application Engineer, Danfoss

F5 Modeling: Valves, Analysis, Performance | 10:30 am - 12:00 pm

Modeling, Simulation and Analysis of a Simple Load-Sense System
Leroy Garciano, Systems and Application Engineer, Danfoss

Improving the Position Control Performance of a Proportional Spool Valve, Using 3D CFD Modeling
Emma Frosina, PhD Student, University of Naples Federico II

F6 New Pump Designs | 10:30 am - 12:00 pm

Design of a Variable Displacement Triplex Pump
Shawn Wilhelm, PhD Student, University of Minnesota

Experimental Characterization of External Gear Machines with Asymmetric Teeth Profile
Ram Sudarsan Devendran, PhD Student, Maha Fluid Power Research Center, Purdue University

Using Helical Gear Form to Reduce Ripple and Noise in External Gear Pumps
Agostino Martini, Manager, Settima Meccanica Co

F7 Improved Quality and Safety, Using FMEA and Component Coding | 1:00 - 2:00 pm

Using System FMEAs to Improve Safety, Quality and Performance in Off-Highway Hydraulic Systems
D. Dean Houdeshell, Manager, Systems & Application Engineering – Americas, Danfoss

Using 3D-Color Coding to Communicate Fluid Power Designs
Vito Gervasi, Director R&D, RPR, Milwaukee School of Engineering

F8 Test Stand Design: Hi-Bandwith and Impulse Fatigue | 1:00 - 2:00 pm

Design of a High-Bandwidth, Hydrostatic Absorption Chassis Dynamometer with Electronic Load Control
Daniel Skelton, Graduate Research Assistant, Purdue University

Energy Efficient Impulse/Fatigue Testing
Timothy Kerrigan, Fluid Power Consulting Engineer, MSOE - Fluid Power Institute

F9 Innovative Applications of Hydro-statics for Small Machines | 1:00 - 2:00 pm

Novel Use of a U-style Hydrostatic Transmission to Develop a Low-Power Dual-Mode Transmission
Wyatt Hall, Engineering Intern, Danfoss

Hydrostatic Baja Vehicle
David Johnson, Student/Applications Engineer, Milwaukee School of Engineering

For additional information, including fees and how to register, click here.

 

 

 

Click here for information about free fluid power seminars being held in conjunction with IFPE and ConExpo/ConAgg.

Click here for information about college level short courses offered at IFPE.

FP-hp magnetic rotational-speed sensors, for use in hydraulic drives with pressures up to 275 bar, feature a 14.7-mm insert depth. The device’s heavy-duty brass housing keeps dirt and moisture out. The sensors operate over a 0.1 to 20,000-Hz range and guarantee high-EMC stability. The sensors also feature a measuring surface pressure resistant to 275 bar.

Rheintacho Messtechnik GmbH, +49 (0)761 45 13 0

We began covering the IFPE Technical Conference decades long before it was called the IFPE Technical Conference. I found a few well-worn bound copies of the proceedings of the National Conference on Fluid Power (predecessor of the IFPE Technical Conference) from 1948, 1950, and other years from more than 50 years ago on the shelves of our archives. In fact, we covered the NCFP even before there was a National Fluid Power Assn., Fluid Power Society, or Fluid Power Distributors Assn. That goes back to before most of us were born.

If you attend the IFPE Technical Conference, half-day short courses, or the free fluid-
power seminars we’re organizing, you’ll certainly help round out your knowledge of fluid power. But networking with others in the industry can prove just as valuable and a lot more fun. The many social events associated with ConExpo and IFPE make for long days and little sleep.  

Aside from the enjoyment of networking with old friends and new, I always like to engage in trivia. I still remember one of the first tidbits I learned at a gathering when I worked for a distributor. I worked in mechanical power transmission then, and I wondered why some pulleys were carried pulleys, while others were called sheaves. It sounded like a very basic question, so I was almost afraid to ask. However, I was still pretty new to the business, so I figured I could play the newbie card to save face. To my surprise, the people I asked did not know the difference. Most of them gave vague answers instead of admitting that they didn’t know.

Then I was talking to a guy who was nearing retirement, and he was happy to help me out. He said a sheave has one or more circumferential grooves, whereas a pulley doesn’t. So a crowned pulley is a pulley, a pulley for a synchronous belt is a pulley, but a pulley for a V-belt is actually a sheave. I hadn’t known that, and maybe you didn’t either.

Once I got involved with fluid power, similar questions arose, such as, “What’s the difference between a hose and a tube?” Naturally, steel or copper tubing is not hose, but what about a length of flexible, nonmetallic material? Hose or tube? I’ve heard a few different accounts, but the one I like best (and that we adhere to at H&P) is that a hose has some sort of reinforcement, whereas a tube does not. So if it’s made of neoprene, or silicone, it’s a tube. But once you reinforce it with nylon or other material, it becomes a hose.

How about pipe and tube? Some people have told me that a pipe is threaded, whereas a tube has to have end fittings attached. This doesn’t wash, because some pipe is welded. My understanding is that pipe is measured by its inside diameter, whereas tube is measured by its outside diameter. That doesn’t really differentiate them, because if I have a hollow cylinder, how do I know if I’m supposed to measure its ID or OD? Maybe I’ll find an answer by networking at IFPE and ConExpo.

With so much going on at IFPE and ConExpo at the Las Vegas Convention Center in a few weeks, it’s hard to find time to fit everything in. These events offer a wide variety of educational opportunities, including the IFPE Technical Conference and college-level short courses. (Our coverage of these sessions begins on page 20 of this issue.) If you’re pressed for time but want to increase your fluid power knowledge, you might consider these seminars addressing topics of high interest.

Each session is free, less than 1 hr, and you don’t even have to register. How’s that for quick and convenient? Sessions will be held throughout the day on Wednesday, March 5 and Thursday, March 6. Your IFPE or ConExpo/ConAgg badge will admit you to any and all of the sessions, which are conducted by professional trainers and industry experts. All seminar sessions will be held in the South Hall Bridge Meeting Complex. Following is a summary of sessions, but be sure to check the Web page at bit.ly/1iPhCXZ because we expect to add more sessions before IFPE begins on March 4. The Web page will also show times for each session, and session times will be posted in the South Hall Bridge Meeting Complex.

Wednesday, March 5, 2014

Morning Session: Best Practices in Mobile Hydraulic Maintenance

Mobile hydraulic systems are powerful, so it’s important to practice safety when maintaining them. This session covers money-saving maintenance techniques for hydraulic systems and how to work safely around them. Presented by Robert J. Sheaf Jr., CFC Industrial Training.

Morning Session: Reducing Leakage and its Environmental Impact

Hydraulic fluid leaks are not only messy, but also unsafe and can cost your company plenty if they harm the environment. This session examines practical techniques to eliminate, reduce, and manage leaks. Presented by Robert J. Sheaf Jr., CFC Industrial Training.

Afternoon Session: Pneumatic Systems in Mobile Equipment

Pneumatic systems are widely used in all types of mobile equipment, so this session explores important issues of mobile pneumatic systems that often are overlooked by those familiar with industrial pneumatics. Presented by Robert J. Sheaf Jr., CFC Industrial Training.

Morning Session: Balancing High-Strength Tubing Selection and Cost in Hydraulic System Design

Hydraulic system engineers who need metal tubing to meet today’s demands for higher system pressure are often faced with limited choices and cost constraints.  This session will explore high-strength tubing options and their impact on system design and how new developments in high-strength tubing give designers more cost-effective solutions. Presented by John H. Wilbanks, Quality Manager, Plymouth Tube Co.

Afternoon Session: Contamination Management in Hydraulic Systems

By far, hydraulic fluid contamination is the biggest cause of hydraulic system malfunctions. This session helps attendees reduce operating costs and downtime through contamination assessment and control. Presented by Robert J. Sheaf Jr., CFC Industrial Training.

Thursday, March 6, 2014

Morning Session: Understanding Mobile Hydraulics

This session provides an overview of the wide variety of pumps, valves, and controls used in mobile hydraulic systems to make mobile equipment more efficient, powerful, and versatile than ever. Presented by Terry Hershberger, Bosch Rexroth Corp.

Morning Session: Electronic Control of Mobile Hydraulics

Picking up where the previous session leaves off, this presentation summarizes electronic pump and valve controls and their advantages over conventional pilot-operated systems in mobile hydraulics. Presented by Terry Hershberger, Bosch Rexroth Corp.

Afternoon Session: Troubleshooting Excavators and Loader Backhoes

After providing an overview of hydrostatic transmissions and other circuits commonly found in mobile equipment, this session examines basic malfunctions that occur and how to identify and correct them. Presented by Robert J. Sheaf Jr., CFC Industrial Training.

Afternoon Session: Troubleshooting Hydraulics in Aerial Lifts

This session opens by reviewing common circuits used in mobile lift equipment, common malfunctions that occur in lift circuits and drives, and how to pinpoint their causes and correct them. Presented by Robert J. Sheaf Jr., CFC Industrial Training.

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