Lean Automation (Integrated Electrical and Hydraulic) Machinery Health. Proportional Directional Valves. LifeSense Hose

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1 Lean Automation (Integrated Electrical and Hydraulic) Machinery Health LifeSense Hose Synflex Thermoplastic Hose with TTC Hose Fittings Eaton EC525 AQP Hi-Temp 4- Spiral Hose Proportional Directional Valves Contamination Sensor Monitor CSM 02 Contamination Control System CCS4

2 Lean Solutions Introduction Perfect interplay between electrical engineering and hydraulics We use 'Lean Solution' to bring together the worlds of hydraulics and electrical engineering in the field of automation. A fully integrated, electro-hydraulic system represents a complete solution for your machine. Automation components such as HMI/PLCs communicate perfectly via CANopen with intelligent Eaton hydraulic valves. The brain of the system is the HMI/PLC which combines control, visualization and data management tasks with stateof-the-art communication in a single device. Via a CANopen fieldbus, the HMI/PLC communicates with drives, I/Os and now with the new KBS valves as well, thus providing full control of machine axis movement.

3 Lean Solutions Introduction Lean the New Way To the Efficient Machine Lean Solution considerably improves the entire value chain starting from planning, engineering, production and commissioning right through to troublefree operation and maintenance of the machine. Eaton's fully integrated electro-hydraulic system provides across-the-board improvements to the productivity and reliability of the machinery while also reducing the costs associated with wiring, testing and commissioning.

4 Lean Solutions Clear Benefits Clear Benefits for the Customer Significantly reduce total cost to design by reducing the costs for engineering 70% as well as for wiring, testing and commissioning 85% Increased uptime and productivity by 10% through predictive maintenance of all connected components of the machine, including hydraulic hoses. Energy consumption of hydraulic system reduced by 50% Use of standard components A uniform software platform Transparency from the controller down to the sensor/actuator Simple diagnostic options for current values

5 Lean Solutions Concept 1 Concept 1: Traditional structure with centralized PLC The use of touch displays and remote I/Os eliminates the need for complex wiring to the central PLC. For the first time the touch display offers a communication connection to an ERP system. A production manager on site is no longer required, since he can now access machine data remotely. Together with the fieldbus, remote I/Os replace complex machine cabling.

6 Lean Solutions Concept 2 Concept 2: HMI/PLC-distributed intelligence The touch display PLC replaces the central PLC. A gateway to the fieldbus is no longer required, the SmartWire-DT line is connected directly to the HMI/PLC. Operating data from the motor feeders, such as motor current, thermal motor load, switching states and trip indications are transferred to the HMI/PLC via SmartWire-DT. Servo drives, frequency inverters and also Eaton hydraulic components are integrated via standard fieldbuses. The flexible architecture reduces both downtimes and retrofitting times.

7 Lean Solutions The Vision The vision: Distributed intelligence from start to finish with SmartWire-DT The visionary Lean Automation structure eliminates the need for remote I/Os and any signal wiring to sensors or actuators. Lean Connectivity brings SmartWire technology directly into the devices. The structure consists of an HMI/ PLC with integrated SmartWire-DT and intelligent remote components. Starting from the display, SmartWire-DT connects electrical switching devices as well as safety components and electrical drives. LifeSense hose monitors the health of hydraulic hose assemblies in real time.

8 Lean Solutions Key Products Tie Rod Cylinders Features Eaton SureSeal system for improved performance and better serviceability Open-Circuit Piston Pumps Featuring robust bearing designs to deliver longer life and reliable operation. Recording States Sensors capable of recording movements mechanically, optically or using capacitive technology. Powering Motors Safe powering and control of electric motors and through them hydraulic pumps, valves and cylinders.

9 Lean Solutions Key Products AxisPro Valves High performance, distributed axis control improves machine performance/ reliability Smartwire-DT Innovative connection technology reduces electrical panel complexity Life Sense Hose Industry first monitoring technology predicts hose failure before it occurs XV-Series Machine HMI Next generation integrated HMI/PLC devices help reduce machine control costs

10 Lean Solutions Case Study Industry: MOEM Customer: Poppe + Potthoff Maschinenbau GmbH Application: Bursting pressure test stand, for testing pipe fittings and hydraulic hose lines Nobody handles high pressure better than Poppe + Potthoff. From high pressure lines, pipe components and precision components to testing equipment and services, the corporate group develops and produces complicated technical solutions for the automotive and service vehicle industries, as well as for shipbuilding and general industrial use. Its current range of projects includes an Eaton test bench with Eaton hydraulic and electrotechnical components. Over the course of the collaboration, Poppe + Potthoff Maschinenbau gained a strong sense of respect for Eaton's work and developed real trust in its partner as a one-stop source for components and expertise in both application areas.

11 Lean Solutions Case Study Labor costs cut by more than 60 %. Industry: Woodworking Customer: Minda Industrieanlagen GmbH Application: For decades in Minden, Germany-based Minda Industrieanlagen GmbH has been a leader in the development of pressing systems for the production of glulam. One new product is a hydraulic pressing system that can be operated from up to 6 remote control panels. Each control panel features an integrated touch-sensitive display, 10 to 60 signaling units and indicator lights, pressure and toggle switches, signaling contacts, an emergency-off switch and an I/O station for third-party SmartWire-DTcompatible sensors. Each control console featuring the traditional setup requires between 3 and 18 hours to wire the sensors. SmartWire-DT cuts the labor associated with that task by more than 60 percent.

12 LifeSense Technology Eaton s LifeSense is a patented hydraulic hose condition monitoring and notification system that monitors the health of hydraulic hose assemblies in real time; detecting internal fatigue, as well as external damage, and providing advance notification the hose is approaching the end of its useful life. Detects and warns of impending failure increased reliability Provides over 50% more hose life Safeguards workers and protects the environment Improves maintenance/operations efficiency automates inspections, ongoing and real-time monitoring Maximizes uptime mitigates unexpected hose failures Available in wired and wireless technology Award-winning innovation 2012 Winner R&D 100 Award 2012 One of industry s best new products of the year, King Awards

13 Synflex Thermoplastic Hose with TTC Hose Fittings Eaton s Synflex thermoplastic hydraulic hoses provide the widest range of fittings available in the industry, with over 400 different fitting part numbers offered with a large range of terminal end configurations. This is a key benefit in being able to service the variety of equipment in the field with imperial or metric thread end connections. Features & Benefits Reduction in fitting inventory Lower overall hose assembly cost

14 Eaton EC525 AQP Hi-Temp 4-Spiral Hose Eaton s new AQP elastomer is the compound used in the tube and cover of the EC525 hose. AQP has proven itself over the years as the best solution for hydraulic hose applications where fluid compatibility and high temperature capability are problematic. EC525 is qualified with the existing TTC12 one piece thru the cover fitting used with Eaton s standard 100R12 4-spiral hoses. Features & Benefits 4-spiral wire construction New version of AQP tube and cover High operating temperature range: - 40 C to +150 C (-40 F to +302 F) Compatible with a wide variety of petroleum based hydraulic fluids Unique Eaton AQP inner tube compound provides improved fluid compatibility, leading to longer hose life and lower maintenance costs Approved for use with Eaton TTC12 4- spiral fittings eliminate the need for skiving and reduces inventory

15 Proportional Directional Valves Proportional Directional Valves Eaton s specially designed injection P/Q valves provide precise control of injection velocity, smooth transition from velocity to pressure control and back pressure control that is highly repeatable to produce parts with tight dimensional accuracy and high quality. Eaton AxisPro Proportional Valves provide integrated programmable control capabilities in sophisticated electro-hydraulic axis control applications. These valves contain both programmable onboard electronics and integral spool Linear Voltage Differential Transformer (LVDT) sensors to provide precise, accurate, responsive axis control capabilities. The valve is easy to configure and customized with application code created by Eaton s Pro- FX Control software.

16 Contamination Control System CSM02 By analyzing the amount and size of solid contamination in hydraulic and lubrication fluids CSM 02 contributes to maintain the efficiency of the system and protects its functionality. Features & Benefits Operates off-line Analyzes the amount and size of solid contamination Easily upgraded with additional sensor modules to measure other important fluid parameters Measures foamed oils accurately Early detection of changes in fluid cleanliness, oil composition and contamination increases Useful for quality control, maintenance, and during initial operations With sensors PFS01 & WSPS05 Typical Applications Immediate and accurate diagnoses enables the operator to influence the system or intervene with appropriate counteractive measures when necessary. Weight: 33 kg Dimensions: 403 x 210 x 666 mm

17 Contamination Control System CCS4 By knowing the particle size distribution of the contamination plus water saturation and fluid temperature the user is able to promptly initiate actions and cost-saving measures before any failure of the system can occur. Features & Benefits Suction and pressure mode (<=420 bar) Exact evaluation of contamination classes according to ISO 4406:99, ISO 4406:87, NAS 1638, and SAE AS 4059 Counting system: > 4 µm(c), >4.6 µm(c), >6.0 µm(c), >6.4 µm(c), >10 µm(c), >14 µm(c), >21 µm(c),,>38 µm(c) Measuring programs: special automatic measuring and conditioning operations, such as single, continuous, cyclic, and offline measurements Output of current and saved measurement values by an RS-232 interface Typical Applications It can be handled in on-line pressurized operating modes as well as for depressurized samplings (e.g., tank sampling). Weight: 11,5 kg Dimensions: 425 (l) x 284 (w) x 155 (h) mm