How would you handle PFAS restrictions? Your link to the cutting edge www.hpmag.co.uk MARCH 2023 p6 p16 Talking Industry Live: Leading industry figures to deliver keynote The invisible contaminant Hydraulic telescopic gantry is put through its paces p20
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Budget 2023 highlights challenges & opportunities EDITOR’S COMMENT www.hpmag.co.uk HYDRAULICS & PNEUMATICS March 2023 3 The most positive outcomes of the 2023 Budget were measures to tackle the UK’s labour shortages and the so-called ‘returnerships’ with skills boot camps and sector-based work academies. ‘ ’ The hydraulics and pneumatics industry is primarily driven by manufacturing, construction, and the engineering sectors, and any changes in government policies and funding can obviously impact these industries, leading to a ripple effect on the hydraulics and pneumatics industry. Therefore, all eyes and ears were on the Chancellor’s recent Budget statement to see if the Government would increase investment in infrastructure projects. Such increases could lead to increased demand for hydraulic and pneumatic systems used in construction and transportation. Equally, the sector was looking for the government to offer tax incentives for businesses investing in green technologies such as renewable energy, which could also lead to increased demand for hydraulics and pneumatics systems that support these industries. So how did the Chancellor do? Chris Barlow, Partner at MHA, says that manufacturers will be buoyed by new incentives to plan and invest. For example, he highlights that the Chancellor has implemented several measures that should allow manufacturers to plan and invest. The full expensing of IT, plant and machinery from taxable profits will provide welcome relief alongside the £1 million annual investment allowance to help manufacturers plan with some level of confidence for the first time in a while. However, he highlights that there were some missed opportunities such as not correcting the previously announced measures to reduce R&D relief for SMEs. He explains that while companies which invest most heavily in R&D expenditure will be eligible for further relief the majority of SMEs will be disappointed that previously announced cuts will remain. Additionally, he explains that the 6% rise in corporation tax, while well trailed, is a missed opportunity to release the tax burden felt by manufacturers. More importantly, the failure to reduce the tax does nothing to make the UK more attractive compared to our European counterparts. Specific infrastructure announcements were also not forthcoming which seems obvious after the Government spent the preceding week to the budget announcing several major transport project delays and reprioritisation. Indeed, many of the announcements in the actual budget itself had no confirmed dates and most likely won’t come into effect until post the next election. So, it was disappointing. The most positive outcomes of the 2023 Budget were measures to tackle the UK’s labour shortages and the socalled ‘returnerships’ with skills boot camps and sector-based work academies which MHA’s Chris Barlow says seems to be a call to over 50s who have left the workforce early. In this respect, the budget was good news - any new measures to reduce the longstanding manufacturing and engineering skills shortage is a step in the right direction. As the Budget highlights, these are interesting times and 2023 will be a period of both challenges and big opportunities, which is why I am extremely pleased to take the helm of Hydraulics & Pneumatics at such an exciting time. Aaron Blutstein Editor
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www.hpmag.co.uk HYDRAULICS & PNEUMATICS March 2023 5 CONTENTS EDITORIAL Editor: Aaron Blutstein t| 01732 370340 e| editorial@dfamedia.co.uk Content Sub Editor: Leslah Garland t| 01732 370340 e| leslah.garland@dfamedia.co.uk SALES Sales Manager, UK & Overseas: Andrew Jell t| 01732 370347 e| andrew.jell@dfamedia.co.uk Italian Sales Office: Oliver & Diego Casiraghi t| 031 261407 f| 031 261380 e| info@casiraghi.info Turkey: Intersmart Media meltem@intersmartmedia.co.uk Managing Director: Ryan Fuller t| 01732 370344 e| ryan.fuller@dfamedia.co.uk Production Manager & Designer: Chris Davis t| 01732 370340 e| chris.davis@dfamedia.co.uk Reader/Circulation Enquiries: Perception t| +44 (0) 1825 701520. e| dfamedia@dmags.co.uk Marketing Executive Hope Jepson e| hope.jepson@dfamedia.co.uk Operations Manager: Emma Floyd e| emma.floyd@dfamedia.co.uk Financial: Finance Department e| accounts@dfamedia.co.uk Chief Executive Officer: Ian Atkinson e| ian.atkinson@dfamedia.co.uk Published by: DFA Media Group 192 The High Street, Tonbridge, Kent TN9 1BE t| 01732 370340 e| info@dfamedia.co.uk w| www.hpmag.co.uk In co-operation with Printer: Warners, UK © Copyright 2023, DFA Manufacturing Media Ltd ISSN 1366-1981 H&P is a controlled circulation magazine, published 8 times a year. Please contact DFA Media with any subscription enquiries. Paid subscriptions are also available on an annual basis at £110.00 (UK), £145.00 (Europe) or £180.00 (Rest of the World) P+P included. The content of this magazine, website and newsletters do not necessarily express the views of the Editor or publishers. The publishers accept no legal responsibility for loss arising from information in this publication. All rights reserved. No part of this publication may be produced or stored in a retrieval system without the written consent of the publishers. 30 16 6 NEWS 16 HYDRAULICS Air is the unseen enemy of effective lubrication and can be equally damaging to equipment. H&P reports. 26 PNEUMATICS While conventional methods for producing hydraulic and pneumatic system components have been practical, the possibility of implementing additive manufacturing can be transformational. John Joyce explains further.. 28 KNOWLEDGE BASE H&P looks at a new partnership to deliver an innovative solution for the floating wind industry. 30 MANUFACTURING & ENGINEERING WEEK PREVIEW 2023 32 APPLICATIONS One of the world’s top fertiliser producers operates a big fertiliser complex in South America. A few years ago, the company started an expansion project that includes three additional phosphoric acid concentration lines. Sulzer was selected to supply the critical evaporator circulation pumps. H&P reports. 34 INTEGRATED SYSTEMS A partnership between test and measurement equipment distributor Hydrotechnik and wireless remote monitoring specialist Mantracourt resulted in a pressure monitoring system for hydraulic rams supporting building foundations against the forces of the River Thames. H&P reports. 38 BFPA Hydraulics & Pneumatics’ issue-by-issue briefing on current activities and views involving the British Fluid Power Association. 40 BCAS Our regular news and events update on the British Compressed Air Society. 42 COMPRESSED AIR By opening a window to visualise their compressed air energy consumption in real time, production teams are defending against rising costs and achieving operating efficiencies with relatively little effort. H&P spoke to Darren Pratt at SICK UK. 46 NEW FACES A selection from our industry’s most recent high-profile appointments. 47 PRODUCTS & SERVICES DIRECTORY 42
NEWS 6 HYDRAULICS & PNEUMATICS March 2023 www.hpmag.co.uk Rotec Hydraulics is celebrating after being named finalists in two categories at the Somerset Business Awards 2023. The well-respected provider of hydraulics, pneumatics and electrical systems is still in the running for both the ‘Large Business of the Year’ and ‘Somerset Manufacturer and Producer’ Award categories. Rotec’s business ethos and its proven ability to thrive despite challenges including the pandemic and the volatility of the marketplace, has earned them a place at the grand final in the ‘Large Business of the Year’ award category. Named finalist for the ‘Somerset Manufacturer and Producer of the year’ category at this years’ awards is testament to Rotec’s innovative use of technology and ability to produce bespoke solutions for its clients. This year is the 18th anniversary of the awards, which are organised by Somerset Chamber of Commerce. The grand final Rotec Hydraulics named double award finalist at Somerset Business Awards will be hosted by BBC Somerset presenter and journalist Claire Carter at the Winter Gardens Pavilion, in Weston-Super-Mare, on 24 March 2023. Somerset Chamber Executive Director, Emma Rawlings, commented: “Despite some really challenging trading conditions, it’s been incredibly encouraging to see so many positive applications from business and charities from across the county – they are doing some great work and we are honoured to be able to highlight that through these awards. “The finalists have come from across the county, representing a wide range of sectors and industries so the final will be a fantastic opportunity to celebrate their many achievements.” Paul Prouse, Managing Director of Rotec Hydraulics, added: “We’re delighted to be announcing Rotec has been named a double finalist at the 2023 Somerset Business Awards. We have been named among the most innovative and forwardthinking businesses operating in the county. “Being named finalist in two categories is a testament to our fantastic, and diverse team of employees who have continued to provide solutions and outstanding products and services to our customers throughout a challenging period for all businesses. “We are extremely proud to have been named finalists for two Somerset Business awards. Investing in and utilising cutting-edge technologies and providing innovative solutions for our clients has always been at the heart of our business.” Leading manufacturing figures to deliver keynote speeches at Talking Industry Live The inaugural Talking Industry LIVE (25 April 2023) keynote address at the MTC will be an interactive, engaging and informal podcast style discussion by Mike Hague-Morgan, Executive Director of Autocraft Solutions Group, and Dr Megan Ronayne, Head of Industrial Technologies & Manufacturing at Innovate UK KTN. Together they will explore how one of Europe’s leading OEM partners for the manufacture, remanufacture and assembly of IC engines and EV batteries transitioned from being a very traditional manufacturer using hand tools and a paper system, to a high-technology company with world-class quality, repeatability and digital traceability which has been the catalyst for such rapid growth from £7m to £70m turnover. Innovate UK’s innovation ecosystem, including Innovate UK KTN and the Catapult Network played a vital role in the digital journey of Autocraft Solutions Group. Mike and Megan will explore how Innovate UK provided this leading powertrain manufacturing partner with collaboration, funding, and vision to give a practical and real-life insight into how companies can achieve similar transitions. The discussion will move on to look at how you can grow your business, through technology adoption and implementation. They will explore the current understanding of digital processes for manufacturers in the UK, the opportunities available via funding, knowledge, and innovation networks, and explain the dynamic benefits to your business including quality, productivity and upskilling improvements. Mike Hague-Morgan is a highly respected figure in the manufacturing industry, with over 30 years of experience in the sector. As the Executive Director of
FLUID POWER MADE EASY www.flowtech.co.uk Pneumatics Hydraulics Industrial Process & Instrumentation • Hydraulic hose assemblies • Pressure testing • Pipe threading • Tube manipulation • Walform tube forming • Kitting • Product modification • Cylinder repairs • Ball valve handle printing EMC Bigger and better than ever! Flowtech’s Engineering Modification Centre (EMC) offers engineering services to our customers. We’ve recently invested £100k in state-of-the-art machinery, expanding the EMC’s capabilities and doubling its size to 4,900 square feet. With a new layout and up-to-date machinery, we’re ready to test, build and modify products to your exact requirements. Flowtech’s highly-trained and certified engineering team work to the strictest standards, ensuring your modifications, bespoke products and kits are of the best quality and reliability. Whether it’s a complete valve, actuator and control package, or a shaft change on a pump, our engineers can provide you with a solution. Contact our team for more information: enquiries@flowtech.co.uk
8 HYDRAULICS & PNEUMATICS March 2023 www.hpmag.co.uk NEWS Autocraft Solutions Group, he oversees a global company that provides bespoke engineering solutions for some of the world’s leading automotive manufacturers. Dr Megan Ronayne is an expert in industrial technologies and manufacturing, with over 20 years of experience in the field. As Head of Industrial Technologies and Manufacturing at Innovate KTN, she leads a team that provides support and funding for innovative manufacturing projects in the UK. Talking Industry Live will provide an environment for delegates to learn about cutting edge technologies and best practice through unscripted panel discussions, presentations, live demos and workshops. Limited to 400 delegates, this unique one-day event will be broken in to five distinctive elements allowing visitors to tailor their own experience learning new skills, meet new suppliers and gain knowledge whilst networking with peers. This format allows visitors to learn new skills, meet with new suppliers and gain knowledge while networking with peers in a high-end environment. There will be three 45-minute interactive panel discussion throughout the day. Audience participation will be encouraged, and questions will be taken throughout the discussions. Topics include robotics and automation, increasing overall equipment effectiveness (OEE) and digital manufacturing, industrial data and artificial intelligence. In addition, there will be two in-depth workshops provided by the event’s content partners. Euchner UK’s session will be on managing equipment safety and cyber security in the modern factory. The second is provided by Rittal/Eplan and will cover smarter panel building. Workshop places are limited to 40 per session so pre-registration is advised. Six 45-minute seminars will also be on offer throughout the day and topics so far include collaborative automation: solving the UK productivity puzzle, mobile robotics: mobile, flexible & resilient – the factory of the future and additive manufacturing: automated 3D printing – exponential manufacturing possibilities. There will also be the opportunity for delegates to see ground-breaking products and innovations from KUKA, Werma, Motor Technology, Novotek, Euchner, Rittal, Eplan, Weidmuller, Omron, BCAS, Charter Controls and many more, thanks for a micro exhibition that is running during the event. There are only 400 spaces available for the event. This year’s event will be held on 25 April 2023, at The Manufacturing Technology Centre (MTC), Coventry. To register your interest in attending, visit the event’s Eventbrite page: https://www.eventbrite.co.uk/e/ talking-industry-live-tickets474610170797?aff=SJPR Science Museum exhibit features MTC apprentices Two MTC Training apprentices are featuring in a permanent exhibit at London’s Science Museum. The exhibit aims to promote STEM (science, technology and mathematics) subjects to youngsters. The exhibit – “Technology Makes it Happen” – is supported by The Gatsby Foundation which is a charity established by David Sainsbury to promote science, education and the arts. MTC Training apprentices Kieran Bullivant and Evadney Enock, who have completed their advanced manufacturing apprenticeships, feature in a video talking about their training and the opportunities that have opened up to them. The exhibition, which opened at the end of last year, is scheduled to stay at the Science Museum for at least 10 years. Kieran Bullivant said they were both privileged to promote a career in engineering and manufacturing, and help encourage youngsters into industry: “We really hope this exhibit will encourage youngsters from all backgrounds into engineering and manufacturing, and an apprenticeship is a great way to start. Apprenticeships give you hands-on experience with all the freedom of not being in thousands of pounds of debt. As well as being able to learn from the ground up, and get that insider knowledge from those who know it best, your experience makes you such a versatile asset to employers.” Evadney Enock added: “My MTC apprenticeship has allowed me to learn while I earn and has opened up a fantastic career path for me. Through my apprenticeship programme I now have skills that will benefit me for years to come.” Kieran is a previous chair of the MTC’s Tilly Shilling Initiative, which aims to encourage diversity and inclusivity in STEM subjects. The MTC was founded by the University of Birmingham, Loughborough University, the University of Nottingham and TWI Ltd. The MTC’s industrial members include some of the UK’s major global manufacturers. The MTC aims to provide a competitive environment to bridge the gap between university-based research and the development of innovative manufacturing solutions, in line with the Government’s manufacturing strategy. The MTC is part of the High Value Manufacturing Catapult, supported by Innovate UK. MTC Training apprentice Kieran Bullivant at the Science Museum exhibit.
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NEWS Hannover Messe 2023 (17–21 April) is set to focus not only technologies for connected, climate-neutral industry, but also provides a forum for a global policy discussion among industry, government, science and social representatives. Carbon-neutral production, artificial intelligence, hydrogen technologies, energy management and Industry 4.0 are the overarching themes of Hannover Messe 2023 according to Dr. Jochen Köckler, Chairman of the Managing Board of the Deutsche Messe group of companies, who explained: “Only the interplay of these technologies will make it possible to sustainably safeguard our prosperity and at the same time drive climate protection forward.” At the world’s leading trade fair for industry, some 4000 companies from the mechanical engineering, electrical and digital industries as well as the energy sector will showcase solutions for production and the energy supply of the future. From the digitalisation and automation of complex production processes and the use of hydrogen to power factories and the use of software to register and reduce carbon footprints, Hannover Messe offers a holistic picture. As Köckler emphasised: “Approaches to solutions for each of the current global challenges will be on display at Hannover Messe.” Hannover Messe will be opened by German Chancellor Olaf Scholz and Indonesian President Joko Widodo. Indonesia is this year’s Partner Country at the industrial fair. https://www.hannovermesse.de/en/hannover-messe-2023/ Industrial solutions for connectivity and climate neutrality at Hannover Messe 2023 STAINLESS STEEL HYDRAULIC HOSE AND PIPE FITTING SPECIALISTS We are the leading manufacturer and stockist of stainless steel hose fittings, tube fittings and adaptors. Call one of our friendly and knowledgeable specialists today to see how we can help. 30 TRADING FOR OVER YEARS CALL 01274 852 066 sales@customfittings.com www.customfittings.com PROUDLY MADE IN THE UK
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NEWS 12 HYDRAULICS & PNEUMATICS March 2023 www.hpmag.co.uk Digitalisation and the Industrial Internet of Things (IIoT) represents the next level of industrial automation. Consultant editor at DFA and chair Andy Pye summarises some of the discussions from the latest Talking Industry episode. There are many ways to catch up if you missed it: Talking Industry episodes are available on demand, and as Podcasts. According to a poll conducted amongst the audience during the event, which asked, “do the green shoots emerging on the foliage outside the studio match those of IIoT in UK manufacturing?”,the answer is: yes and no. Only 10% judge themselves to be at an advanced level, while the remaining 90% were approximately equally divided amongst “Not sure where to start”, “At the start”, and “Midway on the journey”. On the panel on this occasion were: Jean-Paul Verheylewegen, Global Sales Manager, MB Connect Line (the IT security company acquired by Red Lion Controls in 2022) Chris Barlow, Sales & Marketing Director, Novotek Alejandra Matamoros, Technology Manager, Manufacturing Technology Centre Luke Walsh, Managing Director, Brainboxes Digitalisation is a journey, so to start with, keep it simple, start small, then scale up. We look at the how to get people and technology on the right road. Leading off, Jean-Paul highlighted the maxim of starting with small pilot projects, whilst having an holistic vision in mind of the overall benefits of digitalising the whole enterprise. Not so much “start small”, but “start smart” as he put it, a concept which all the panelists agreed. Jean-Paul explained that there are two parts to an IIoT project: the first part is collecting data in the field from a variety of IoT devices, scale it, process it and then push it to a higher system, as an MES. The second part is generating value out of that data and distributing it. Two different sets of skills are required: people with an IT knowledge may have difficulties with data acquisition from the field, people with a more OT profile may have difficulties with cloud systems, value creation or distribution, because the tools that are used there require more specific IT competencies. The theme continued with Chris, who focused on how to manage the data flow issues, all the way from acquisition to usage and thence to storage. Like Jean-Paul, he acknowledged the importance of getting people on board the journey, citing potential conflicts for budgets and even personnel themselves. He explained the differences by comparing a SCADA system, used for real-time visualisation and the control of a manufacturing system, with an MES, which is about bridging business systems and control systems, and managing people and processes and all of the data involved in transforming raw materials into finished goods. Luke interjected that before you can choose between a holistic approach or a piecemeal approach to digitlisation, you need to convert the workforce from being (possibly) Digital Sceptics towards being Digital Champions - in his view, you cannot do this overnight, but in a slow measured approach. Alejandra spoke at our Talking Industry Live programme in 2022 at the Drives and Controls Exhibition in 2022. She remains not only the first person hailing from Venezuela to take part, but also the first from the continent of South America. With the exception of Antarctica, we now have featured at least one person from every continent. Here, she discussed the differences between the traditional hierarchical ways of integrating production systems and the IIoT methods. What are the potential and challenges of networked production systems? She said that at the MTC, the emphasis is to take the that holistic view, to discover and understand that long term vision. That doesn’t come with only bringing the seniors to that meeting, but involving all key stakeholders from those processes. Then, and only then, you can start delivering the project in smaller chunks. So start small, but to plan for that with a proper technology roadmap that takes you through the whole transformation journey. Unusually, we concluded the formal part of the discussion with a demonstration, in this case of the Brainbox smart energy monitoring system, which utilises IIoT connectivity to efficiently capture, aggregate and analyse plant-wide energy data. This is a great example of a small step which delivers an immediate return to the bottom line. Luke cited an example where one company discovered that they had been operating on their backup compressed air system for months without even knowing! With current energy prices, it is no surprise that the machine elicited great interest from several attendees in the chat. We could not let our panelists go without asking them about the future of AI in manufacturing, as part of the digitalisation process. Luke jumped in to say that in his view digitalisation must come first. “AI has gone from being peddled as snake oil to actually having a legitimate place within the environment of manufacturing. And its legitimacy is only just starting to kind of show itself to us. AI depends on digital data and can manipulate digital things exceptionally well.” Chris added that predictive maintenance is an area which benefit greatly from elements of machine learning. There may be other areas to find that will probably be going to be where the greatest proliferation will occur, at least in the beginning. Alejandra expressed reservations about the safety and ethical aspects associated with using artificial intelligence algorithms. “We need still to evolve warranty policies that will actually define the concerns and the boundaries of how far AI can actually be taken,” she suggested. Jean-Paul concluded that AI works on data and (as a comment in the chat pointed out) regardless of the potential capabilities of AI in the future, companies need to digitally transform first. As was shown in the poll, we are still in the process of digitising industry. The methodology is still being built. He sees AI as a new tool that will evolve to be helpful in interpreting data. Talking Industry: IIOT, digitalisation & Industrial Communications - smart steps to an AI future?
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Innovation, insight and future inspiration Celebrating the advancements in manufacturing & engineering excellence and innovation 7-8 June 2023 | NEC Birmingham INCORPORATING There has never been a more important time for our sector to pull together and to work together, to create a shared agenda and Manufacturing and Engineering Week will do exactly that. I am delighted to be part of the Advisory Board and that MAKE UK are a partner of this groundbreaking event.” Stephen Phipson CBE, Chief Executive, MAKE UK and M&E Advisory Council Chairman Register your interest here: www.mandeweek.co.uk/ register-interest Find out more at www.mandeweek.co.uk @mandeweek2023
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HYDRAULICS 16 HYDRAULICS & PNEUMATICS March 2023 www.hpmag.co.uk Bubbles in a lubrication system can undermine operating efficiency, inhibit heat removal, increase wear, and, thus, lead to higher maintenance costs. Too often, equipment operators dismiss air contamination as inevitable. But there are steps that maintenance personnel can take to reduce or eliminate the harmful effects of air contamination. Gas-toLiquids (GTL) hydraulic oils offer faster air release and better foam control compared with mineral base oils of the same viscosity. Air intrusion can take many forms, but foam and entrained air represent the biggest threats to equipment. Entrained air refers to bubbles suspended below the fluid’s surface that create air pockets in the lubricants. Foaming results when the bubbles rise to the surface of the hydraulic fluid or other lubricants. In both cases, the air pockets can impede the flow of fluids and leave equipment vulnerable to wear. Surface foam in well-designed and correctly filled oil sumps rarely causes issues during equipment operation. However, foaming may indicate more The invisible contaminant fundamental problems such as oil contamination or degradation. Excessive foaming can cause the oil level to drop so much that the system inlet becomes exposed at the surface, which results in oil starvation. Excessive foaming also can cause the oil to overflow onto potentially hot surfaces. Although foaming is more visible and tends to concern maintenance personnel most, entrained air causes the most damage and the greatest loss of efficiency. Entrained air in a lubrication system can be harder to identify because it has few external or visual indicators. Air becomes entrained through normal engine vibration, flow surges from retracting cylinders, leaks, incorrect oil level control and working on slopes. Entrained air can cause cavitation, micro-dieseling and increased noise or vibration, all of which can lead to excessive component wear. It may also reduce equipment power, responsiveness, and efficiency. Tackling foaming The nature and extent of foaming result from the properties of a lubricant’s base oil and the additive packages in the formulation. Consequently, antifoaming additives are typically used to control excessive foaming. Unfortunately, most of these additives rely on large silicon particles that reduce the surface tension and cause the bubbles to rupture. Industrial applications such as hydraulic systems typically have filtration systems designed to screen out such large particles, which undermines the effectiveness of the additives. Shell Lubricants has studied the causes and effects of air contamination and has developed a deep understanding of foaming and entrained air and how they interact with a wide variety of systems. Working with equipment manufacturers and researchers, Shell Lubricants identified and tested almost 10 plausible antifoaming candidates, five of which had good filterability performance. The most promising, which are based on silicon antifoaming agents, have excellent foam control and product compatibility, and, importantly, remain effective after filtration. Shell’s tests found that adding siliconAir is the unseen enemy of effective lubrication and can be equally damaging to equipment. Shell Lubricants* has developed Gas-to-Liquids (GTL) hydraulic fluids for faster air release and better foam control. H&P reports.
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HYDRAULICS 18 HYDRAULICS & PNEUMATICS March 2023 www.hpmag.co.uk based antifoaming agents to an industrial lubricant could reduce foaming by 50%, even when the fluid was cycled several times through a fine filtration system that screens out particles greater than 3 ?m. Optimising the antifoaming chemistry with a supplementary antifoaming agent also helped to suppress foaming after fine filtration, although it often needed a mixture of antifoaming agents to achieve the desired results. Understanding air entrainment and foaming To improve fuel and energy efficiency, manufacturers are making equipment designed for higher loads and pressures with smaller reservoirs and tanks. This means that the oil spends less time in the sump, so must have better air and water separation properties. At the same time, most equipment operators demand longer oil-drain intervals to reduce maintenance and lubricant costs. Consequently, the oil must work harder for longer, which results in higher temperatures that can affect its ability to release air. All these factors mean that lubricants with excellent air-release properties are more important than ever. In tests conducted at RWTH Aachen University, Germany, hydraulic fluids using synthetic base oils, such as gas-toliquids (GTL) fluids, combined with a performance additive package, had bubbles with much larger diameters than fluids using mineral base oils. These larger air bubbles in GTL fluids rise to the surface quicker than smaller air bubbles, which results in GTL fluids having superior air release performance. However, balance needs to be struck in a lubricant formulation for both good foaming and good air entrainment properties. Silicone-based additives, for example, are excellent anti-foaming agents but are poor for air release. To address this problem, Shell’s base-oil systems using a technique developed at Stanford and recorded the time for each bubble to coalesce. The bubble rupture rates correlated well with the bulk foam measurements from industry-standard tests such as ASTM D892. Furthermore, the team observed that multicomponent base-oil systems stabilised the bubbles more than the single-component systems. In multicomponent systems, as the lighter components evaporated, the surface tension of the oil increased and created small flows on the bubble surface like wine droplets clinging to the side of a glass. These flows drew more oil to the top of the bubble, thereby thickening its wall, which made it less likely for it to burst. However, in single-component systems such chemically driven flows were missing, which resulted in faster bubble rupture through gravitational drainage. The research team is now developing mathematical models for determining the effects of antifoaming agent distribution and evaporation on foam stability that will enable them to simulate how pure or blended oils might perform before and after filtration. They will then apply their findings to designing formulations that reduce foaming. Shell is incorporating many of these findings into its product development and continuing to research this vital issue. It believes that these ongoing studies will have a significant impact on the development of foam-resistant lubricants and combat the unseen enemy of air contamination in lubricants. www.shell.com/lubricants *Shell Lubricants refers to the various Shell companies engaged in the lubricant business. statistics and chemometric group, working with researchers at Shell Technology Centre Houston and Milwaukee School of Engineering, USA, helped to find, map and screen multiple base-oil combinations of the same viscosity to determine the best formulas for faster air release. They found that GTL base oils had exceptional air-release properties compared with mineral base oils of the same viscosity. The group developed fully formulated, prototype GTL hydraulic fluids using an optimised base-oil mixture and performance additive package. The fully formulated GTL hydraulic fluid had a much better airrelease time than a fluid with a standard base oil and the same additive package. Shell scientists also undertook to understand the fundamental mechanics behind foam rupture by carrying out a joint collaborative project with Stanford University, USA to study bubble rupture dynamics. The team conducted singlebubble rupture studies on a range of
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HYDRAULICS 20 HYDRAULICS & PNEUMATICS March 2023 www.hpmag.co.uk Engineers at Enerpac Heavy Lifting Technology in the Netherlands have been putting their newest hydraulic telescopic gantry, the Super Boom Lift (SBL) 600, through its paces ahead shipment to Australia. The three-stage SBL600 gantry has a lifting capacity of 6000 kN and Hydraulic telescopic gantry is put through its paces features a foldable boom, allowing ease of transportation on standard flatbed trucks. With a maximum lifting height of 10.6m, Enerpac has a rigorous testing regime for the SBL600. Witnessed by a representative of Lloyds as third-party proof of testing, the two-part test procedure comprised: a static load test and Factory Acceptance Test. The SBL600 hydraulic gantry has a first stage lifting capacity of 6000 kN, 5000 kN at the second stage and 3700 kN at the third stage. During the static load test each individual gantry leg was subjected to 125% of its load capacity at all three stages. The static test was followed by Factory Acceptance Testing covering all functional aspects of the gantry. This included lifting with 110% of the safe working load of the SBL600 in the upper 3rd stage (10.6m), as well as, testing all gantry movements including the travel of the machine along skid track. Enerpac gantries are used in a wide range of working environments. During earlier testing, the SBL600 was subjected to a Type approval sideload test which ensures compliance with ASME B30.1, an important industry standard that covers heavy lifting equipment such as hydraulic jacks, hydraulic gantries and strand jacks. Tom Eggert, Global Product Manager, Enerpac Heavy Lifting Technology, commented: “All our lifting systems are subject to a rigorous testing regime. ensuring safe and compliant equipment for demanding machine moving and industrial applications. “We apply the same level of rigor to both our new systems and those we refurbish. Our commitment to safety is also reflected in the SBL600 design.” As standard, the SBL600 includes Enerpac Intellilift wireless controls providing users with a safe and reliable way to operate the gantry. With no cables, there are no tripping hazards or risk of incorrect connections. Built-in safety alarms are included to alert operator of unsafe conditions and stop gantry operations. Moreover, each gantry leg has a built-in hydraulic pump which eliminates trip hazards by removing the need to connect hoses and makes the equipment easier to set up. In addition to ASME B30.1, the Enerpac SBL600 gantry complies to CE, UKCA and other safety standards. Accessories for the SBL600 include header beams, skid track and side shift units to shift a load along header beams utilising the Intellilift wireless controls. www.enerpac.com
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HYDRAULICS 22 HYDRAULICS & PNEUMATICS March 2023 www.hpmag.co.uk SICK has expanded its non-contact magnetostrictive linear encoder portfolio with the launch of a versatile product family for wide-ranging industrial applications. The DAX linear encoders precisely determine the absolute position of pistons in hydraulic cylinders, as well as reliably monitoring linear motion in many common industrial machines. The SICK DAX linear encoders have been designed with a flexible product concept to make specification quick and easy for both new and existing users, using a unique online configuration tool with options for additional customisation. They therefore offer a timesaving way for cylinder manufacturers, OEMS and end-users to access a reliable source of supply. The DAX encoder family has industry-appropriate measuring ranges for countless applications as diverse as packaging machines, wind, hydro and solar plants, wood processing machinery, or medical technology. The encoders offer spacesaving benefits for new machinery, as well as backwards compatibility with existing installations, and can be customised to work with all common magnet types. Darren Pratt, SICK UK’s Market Product Manager for Measurement and Instrumentation, explained: “The DAX encoder represents an important milestone in the development of SICK’s encoder portfolio.” “The encoders open up the availability of our magnetostrictive technology to industrial users for the first time. “In just a few steps, SICK’s Online Configurator guides the user through the specification process to generate a part number and create an online order. Thanks to the platform concept of the DAX, application-specific versions can be generated quickly. There is also the flexibility of further customisation for new machine designs, or to enable adaptation to existing machines, including where proprietary magnets are already in situ.” The DAX is being launched with three housing designs: one for integration into industrial hydraulic cylinders; a low-profile type with block magnets for mounting in tight installation situations; and a version with an integrated slider that guides the position magnet, easing the requirements on alignment during mounting. Integration into existing or new machinery is straightforward using standard mechanical interfaces. For electrical installation, the DAX product family offers a CANopen as well as an analog output for either 0-10 VDC or 4-20 mA. Via the CANopen variant, operators have access to diagnostic capabilities to monitor both sensor parameters and environmental conditions, including the magnet signal, temperature, piston cycles/travel distance, power supply and operating hours. Diagnostics can also output speed and time profiles to monitor for changes in machine performance over time. In addition, the DAX encoders offer significant protection to ensure machine reliability in conditions where the power supply is vulnerable to fluctuations. The DAX offers integrated overvoltage protection to enable continued operation despite power spikes, while under-voltage conditions are alerted to the machine operator. Machine designers are afforded significant flexibility to install the encoders in the tightest machine spaces, thanks to a minimal damping zone and an available measuring range between 50mm and 2500mm, individually configurable in 1mm increments. Specific variants of DAX can also use multiple magnets to provide differential values between positions along the measurement range, e.g. providing an output directly proportional to the amount of separation on a press. This feature can also be useful for example, to enable machine adjustments for format changes. The SICK DAX encoders offer all the advantages of noncontact, wear-free magnetostrictive technology to measure absolute position, so no reference run is required. The linear encoders have an enclosure rating of IP65 and IP67, as well as a temperature range between -40 °C and +85 °C. Their rugged design and high shock and vibration resistance ensures longterm machine availability even under harsh application conditions. www.sick.co.uk SICK develops non-contact linear encoders around flexible product platform
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HYDRAULICS 24 HYDRAULICS & PNEUMATICS March 2023 www.hpmag.co.uk Danfoss Power Solutions has launched a range of high-performance hydraulic crimping equipment and tooling in Europe. Designed to help customers and partners manufacture reliable hose assemblies, the tools now available include crimping, cutting, insert pushing, marking, and skiving machines. With the launch of its tooling portfolio in Europe, Danfoss now offers easy access to the best-suited machines for its leading hose brands, including Aeroquip, Boston, Synflex, and Winner. Using tooling matched to specific Danfoss hoses and fittings accelerates production speeds, ensures optimal assembly performance, and minimizes the risk of assembly errors that can cause leaks or safety issues. Furthermore, Danfoss provides clear technical guidance on compatible hoses and fittings, as well as the best assembly methods for each hose in its portfolio, saving customers and partners significant time and effort. “Tooling is an investment that’s crucial to get right,” said Salih Karayagiz, EMEA product manager, Rubber Hydraulic Hose and Fittings, Danfoss Power Solutions. “With our broad portfolio of high-quality machines and matched hoses and fittings, we can help customers and partners identify right-sized solutions, both financially and technically, to meet their needs. They’ll benefit from an optimal technical match, while saving time and resources that would otherwise be spent researching appropriate tooling.” The new tooling portfolio features a broad range of equipment ideal for varied working environments, from mobile workshops to full hose assembly manufacturing branches. Seven manual, workshop, and production line crimping machines form the core of the portfolio, along with a wide range of accessories. These versatile and durable machines use the popular open-throat design, enabling easier and faster crimping of even 90degree elbow pieces without the need to remove all the dies. The ability to mount machines on work vehicles makes the crimpers even more adaptable, allowing hose assemblies to be created at the application site. The tooling portfolio is backed by an array of support services, including repair, recalibration, warranty, and a contact hotline. Karayagiz added: “From field work to high-volume production, our tooling portfolio can meet any need and help drive long-term return on investment by reducing costs and increasing efficiency. “We also remain committed to engineering new tooling capabilities, such as digital connectivity, to help customers further decrease costs and become even more efficient in the future.” www.danfoss.com Complete hose assembly tooling portfolio launched
• Pig’s Tail® Protective Wrapping is designed to protect hydraulic and pneumatic hoses against impact and abrasion. Also suitable for protection of cables including fibreoptics either singular or bundled. • It is a heavy duty form of spiral protection suited to heavy industrial applications. • Made from High Density Polyethylene (HDPE). • Can be used for single hoses or multiple hose bundles. • Operating temperatures -50°C up to +120°C. • Suitable for use with all hydraulic fluids including glycol and phosphate ester based products. • Rounded edges for enhanced performance and safe handling. 0114 349 0766 info@plascompo.com www.plascompo.com PIG’S TAIL Wrapping ALSO PIG’S TAIL RAIL • Flame Retardant – UL94 class V-0 • Complies with EN45545 HL2 • Suitable for use in underground rail Plascompo_H&P_July 2020 Half Pig's Tail.qxp_Layout 1 13/07/2020 17:30 Page 1 HYDRAULICS - PNEUMATICS - ELECTRICAL HIGH QUALITY ENGINEERED SOLUTIONS Services include systems design, build, maintenance & repair, accumulators, filtration, hose & kitting, electrical mechanical services & component distributors of many leading brands. www.rotec.net sales@rotec.net +44 (0)1823 348 900 .............. Half page BFPA Yearbook 2023 146x210mm_v2.indd 1 23/01/2023 12:46:02
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