Presentation: Replacing HPUs and Hydraulic Cylinders… Avoid the Risks, Experience the Benefits

July 27th, 2021

1 Agenda – Topics

• 101 • Advantages / Challenges • Hydraulic Replacement Considerations • SHA Solution • Application Examples – Converting from an HPU

2 Hydraulics 101 Traditional (basic) Hydraulic System

• Pascal (1648) • Pressures (on a confined fluid) provide equal force in all directions which can be harnessed • Bernoulli (1738) – water mills • Fluid speed & pressure relationship • Bramah (1795) • Patented the first

Symbols

$12b Worldwide Market (Hydraulics) 4 Traditional Hydraulic System Advantages • Robust – Proven Technology • Low inertia, can be almost • Compact & Powerful instantly reversed • Known to withstand Shock • Can quickly repair – ease of Loads maintenance • Higher speeds, with High forces • No mechanical metal-metal wear • Self lubricating items - - threads, gears, belts, cams etc • Can run to extreme positions • with no damage Can operate multiple cylinders • • High temp tolerance – no sparks Spare part inventory • • Constant force regardless of No mechanical brake required speed • Ability to view pressures during operation

5 Hydraulic Cylinder Challenges • Pumps run continuously (inefficient), are oversized & are noisy • Pipes, hoses lead to environmental issues + maintenance & contamination issues • Temperature variations (viscosity) can change the performance characteristics • Requires significant floor space • Are sized to run a finite number of cylinders – not a flexible design • Possible high transients causing failures • Complex control loops, costly for coordinated motion & accurate control • Difficult fieldbus integration & diagnostics

6 Costly HPU Intangibles

• Cost of HPU ownership – Engineering / Design – Installation – Maintenance – Continuously Running Motor (Inefficient) – Floor Space – Downtime – Environmental Cleanup – Disposal

7 HPU – Efficiency Costs

30%+ losses 푄 ∗ 푃 ℎ푝 = 1,714 ∗ 퐸푚

Q = flow (GPM) P = pressure (psi) Motor / Pump Sizing considerations: Em = pump mech eff - Pressure drops / length of hoses - Connectors 90deg bends etc - Valve loses - Flow loses • Many times, the motors are sized to run continuously at ~1.2x – 1.5x required loads • 2½ times for internal combustion engines • 30% - 40% Efficiency Savings using the SHA comparing only the HP used • Continuously running motor costs about $800/yr/HP (assuming 0.10$/kWh) • E.g. for a 10HP requirement: • Size a single HPU 15HP motor, the costs to continuously run: ~$12,000 per year • SHA – 10HP, 30% duty cycle costs are ~$2,400 per year (~80% savings)

8 Replacement Considerations

20 HPU Replacement Considerations • Understand the mechanics of the • Understand the existing controls – Flow control, position, force, open loop, closed loop etc – Hydraulic circuit is helpful • Understand the cycle time, load zone or clamping • Understand the system response needs, inertias • Does the system use a counterbalance valve (regen) • Do some simple moving-mass calculations for estimated HP needs • Reliability considerations • Any future desires to enhance the system • Gather as much data as possible – Take videos (for timing and reference) – Cylinder / Rod Sizes – Size of the HPU motor • How many cylinders are on the HPU, how many are running at the same time? – Operational pressures during the process – Environment (Temp, Moisture, Debris etc) – Orientation (locking etc) – Mounting, available space Not every Hydraulic system can be converted to Electric… Loads, Speeds, HP needs, Inertias all need to be considered

10 Electric Technology Option • Electrical (EMA) Advantages: - ACME Screw • Ease of control (position, speed etc) - Ball Screw – Control 101 - Roller Screw • Easy to modify parameters / reconfigure • Power on Demand • No hoses, no leaks etc 40,000 lbf • Flexibility (178 kN) • Simple interface to a PLC – Fieldbus Connectivity – Data Collection – Diagnostics

Limited Strokes

EMA

11 Preferred Solution – SHA (Smart Hydraulic Actuator) Combines the advantages of both while solving the challenges

12 Combines the advantages of both EMA v. SHA technologies while solving the challenges

EMA Challenges: SHA Solutions: • Gears, roller & ball screw actuators are • No metal-to-metal wear complex & wear out – metal-to-metal wear s • Shock loads • No issues with Shock loading • EMAs require maintenance • No maintenance • Have a finite life (L10) • No finite life, rod seal update • Require expensive load cells for force • Can simply use the internal pressure control sensor • Require a brake to hold position • Simple check valve to hold position • Backlash issues • No backlash • Need to be preloaded for precision • No preloading • Are large & very costly at higher loads • Very cost effective at higher loads (~>5,000lbf) s • High IP ratings are difficult to achieve • IP65 is standard, options are available

13 Combines the advantages of both Hydraulics v. SHA technologies while solving the challenges Hydraulic Challenges: SHA Solutions: • Pumps run continuously (inefficient), are • On Demand Power oversized & are noisy s • Pipes, hoses lead to environmental issues • No pipes and hoses, no leaks + maintenance & contamination issues s • Temperature variations (viscosity) can • The Servo Control compensates for any change the performance characteristics viscosity variations • Requires significant floor space • Compact compared to an HPU system • Cannot back-drive through the valves • The SHA can be back-driven if desired • Are sized to run a finite amount of • Can be easily coordinated / synchronized cylinders or added • Difficult to upgrade / add – not flexible • Simple to upgrade – very flexible • Possible high transients causing failures • The servo system controls the transients • Complex control loops, costly for • Standard control loops are used coordinated motion & accurate control s • Difficult fieldbus integration & • The popular fieldbuses are available – diagnostics simple integration

14 “This product is amazing” “Where has this been?” Quick Product Review

“This is one of a few bad ass “The All-in-One is a big products available to sell today” advantage”

10 SHA – Basics • Simple – Closed system • The power transmission method is (virtually incompressible) • Very efficient method • No mechanical binding wear items • Any stroke is available • Most efficient actuator on the market • Up to 42T capability (std) – can be paralleled (synchronized)

• Zero-Max couplings • Positive Displacement Reversible Pump • No hoses, no thread connections

16 Reliability: SHA – Hydrostatic Sealing

lateral bushes (pressure plates) casing gears

To increase flow, the gears get longer

lateral lubricating gap

0.7GPM 3.3GPM 7.8GPM

17 SHA – Hydraulic Circuit

Flow (Speed) • Simple Circuit + Q2 Q1 • Optional Valves (no brake) • Servo Control • Four Quadrant Control +

• Position & Force Control - PSI (Torque)

Reservoir Reservoir • Very Efficient

Cylinder Q3 EXT Press Q4 Sensor -

xx

RET Press Optional: Sensor - Cavity Plug Relief Valves - Check Valve M - Solenoid

Reversible (CW & CCW) xx

18 Example Product Configurations

Parallel Standard Parallel xx” Spacer In-Line 90 Degree Behind PU All-in-One 90 Degree Attached All-in-One Middle Enclosure 24Vdc – IP68 Totally Enclosed 180 Degree Customer Supplied Motor

45 degree (custom)

19 Minimum Hydraulic Fluid Volume

A 5HP gearbox A 5HP HPU with 50ft contains ~120oz of of ½” hoses contains fluid ~380oz of fluid

SHA Environmental Advantages Kyntronics S12C20-23 • Closed system cylinder, rated ~10,000lbf, • Minimal amount of fluid 8" stroke contains ~14oz • Minimal risk of contamination of fluid

20 All-in-One Solution • What other actuator OEM • Sizing • STD software provides a total solution? • STD drawings • Tested • Some of our partners also provide the all-in-one

Actuator

Work (ft-lbs)

14 in Stroke Power.Out (ft-lbs/sec) 6 sec total cycle

Power Out (Watts)

1500lbs

21 Hydraulic Replacement Examples

8 HPU & Hydraulic Cylinder Replacement – Auto Tier 1

5,700 lbf to 23,000 lbf

Replace the messy hydraulics (11) Actuators replaced antiquated HPU system • Knicker SHA Advantages • Shear Blade • Increased throughput & quality • Shear Clamp • Notch Shuttle • Reduced maintenance • Notch Punch • Provided unique configurations to fit into their machine • Power on Demand – more efficient & quieter • Better position control Industries • Automotive

23 Packaging – Blister Pack Machine

Cylinders Eliminated

HPU Eliminated Customer removed two (2) cylinders and an external HPU from the die cutter SHA Advantages • Replaced (2) cylinders & an HPU SHA Replaced (2) • Eliminated the hydraulic hoses & issues cylinders and an • Provided a unique configuration to fit into HPU their machine • Power on Demand – more efficient & quieter • Better position control Industries • Increased quality • Packaging

24 Metal Forming Press for Airbag Components

Metal forming Press Actuator 8,000 lbf (36 kN)

The Machine Builder’s end customer specified “No Hydraulics” on their new presses. The SHA addressed this request while providing better position control and improved quality.

SHA Advantages • Improved process control – using Position and Force control • Eliminated the HPU, hoses and other hydraulic components; Industries eliminating leaks, saving energy and reducing space required • Automotive • Metal Forming

25 OEM – Dry Ice Pelletizer

Automated Dry Ice Pelletizer 22,000 lbf (98 kN)

The Machine Builder wanted to remove the HPU and its contamination. Desired a total solution including an HMI and a complete cabinet. Wanted to eliminate the noise and integrate their simple PLC into our system.

SHA Advantages Eliminated • All-in-One – integrated machine logic • HPU, Hoses etc • Increased throughput and quality • PLC / I/O • Improved process control – using • Relay logic Industries Position and Force control • Misc Control Buttons • Medical • Packaging

26 Punching & Piercing

Punching (Coining) operation Punch & Pierce Actuators 58,000 lbf (258 kN) End Customer Specified “No Hydraulics” on this New Machine

SHA Advantages • Eliminated the HPU, hoses and other hydraulic components; eliminating leaks, saving energy, reducing space required and met the customer’s specification Industries • Improved process control – using Position and Force control • Appliance • Used with Rockwell Automation (Allen-Bradley) motors & controls • Automotive • Metal Forming

27 Clamp, Shear, Punch - Hydroforming Machine

Shear Axis Clamp & Punch Axes Shuttle Axis 15,000 lbf (67 kN) 15,000 lbf (67 kN) / 23,000 lbf (103 kN) 6,000lbf (27 kN)

The End Customer wanted to avoid messy hydraulics with their new machine. The Kyntronics SHA made it possible. SHA Advantages • New machine produces 25% more parts in a smaller footprint • Eliminated the HPU, hoses and other hydraulic components; eliminating leaks, saving energy and reducing space required Industries • Improved process control – using Position and Force control • Automotive • Used with Rockwell Automation (Allen-Bradley) motors & controls • Metal Forming

28 Food Processing End User

Actuator shuttles racks of meat (smoke/flavor/drench chamber) 2,000 lbf (9.6 kN) 55in Stroke Stainless Steel Enclosure w/HMI

The end user is moving away from Hydraulics and requires a possible caustic washdown robust solution. The SHA is an epoxy coated, IP67 actuator. Looking at using Kyntronics across multiple plants.

SHA Advantages • Improved process control – using Position and Force control • Eliminated the HPU, hoses and other hydraulic components; eliminating leaks, saving energy and reducing space required Industries • Food Processing • Medical

29 Appliance Manufacturer

(14) Servo Actuators (7) Clamp – [12,000lbf] 15.5Nm (7) Pierce – [46,000lbf] 26.9Nm (Duplication for spares)

Kyntronics is spreading across multiple plants, the plant’s desires to minimize / eliminate Hydraulics on new . The SHA addressed this request while providing better position control and improved quality.

SHA Advantages • Improved process control – using Position and Force control • Eliminated the HPU, hoses and other hydraulic components; Industries eliminating leaks, saving energy and reducing space required • Appliance • Automotive • Metal Forming

30 4 Welding Manufacturer – Yoke Press

Presses the yoke onto a drive shaft & holds while being welded (3) Large Servo Actuators (3) 84,000lbf [34.1Nm]

Kyntronics eliminated the HPU system, provided the same actuator for multiple locations on the machine. Used a bellows for weld debris.

SHA Advantages • Improved process control – using Position and Force control • Eliminated the HPU, hoses and other hydraulic components; Industries eliminating leaks, saving energy and reducing space required • Automotive

31 Forestry / Lumber Processing

Challenges: 1. All-in-One Solution Chip Head Positioner Actuator 8,000 lbf (36 kN) 2. Eliminate hazardous hydraulics Front Trunnion Mount 3. No EMA (will not live through the shock loads & environment)

SHA Solution: • All-in-One Solution – Programmable Position & Force • Significant power, replaces the HPU without sacrificing power Industries • No hoses, no leaks, environmentally-friendly • Forestry / Lumber • Highly resistant to shock loading

32 Light Truck Axle Assembly Press

Assembly Actuator The SHA Eliminated the use of Hydraulics which made 45,000 lbf (200 kN) the Machine Design Simpler and more Space-Efficient

SHA Advantages • Improved process control – using Position and Force control • Eliminated the HPU, hoses and other hydraulic components; Industries eliminating leaks, saving energy and reducing space required • Automotive • Used with Rockwell Automation (Allen-Bradley) motors & controls

33 AGV OEM – Forklift Project

Automated ForkLift 2,000 lbf (8,900 N) 24in Stroke

Challenges: SHA Solution: 1. All-in-One Solution (48Vdc) • The All-in-One 48Vdc total solution 2. Eliminate hydraulics – HPU • Compact solution 3. Extended life – Roller Screws will not meet • Precision position control 4. Fieldbus Integration – CANbus (unique) • Integrated force feedback for load verification

34 Military – Lifts, Barriers etc

Navy Challenges: 1. Retrofit existing cylinders – high speed & load 2. Replace failing EMAs and complex-messy Hydraulics 3. All-in-One solution 4. Coordinated motion (run multiple cylinders

simultaneously) JBD 5. Redundancy & Manual Lowering Cylinder 6. Space Constraints Central Manifold

MRV

Lock Lock Lock Lock Lock 2 Solenoids 2 2 Solenoids 2 2 Solenoids 2 2 Solenoids 2 2 Solenoids 2 SHA Solution: 1 1 1 1 1 1 1 1 1 1 • Used COTS Power Unit RVs RVs RVs RVs RVs • One Supplier, One Solution • Synchronized Servos • Provided a Redundant • Reduced Space & Clean M M M M M

Reservoir Reservoir Reservoir Reservoir Reservoir

35 Servo Power Units

• Standard Power Units connected to the customer’s cylinder – Two pipes / hoses – Includes the reservoir • Servo Motor and Drive Control – Uses our Proven Software - - Position, Force… – Fieldbus Integration • Can be paralleled to meet load and speed needs • Redundancy is available

36 SHA Advantages vs. Hydraulics

• Single Source Solution • No hoses – No threaded connections – No leaks • Power-on-Demand – Very Efficient • Lower cost of ownership • Quieter (does not run continuously) • Takes up less floor space • Minimal maintenance • Most reliable actuation solution available today • Versatile configurations for machine fit • Accurate / Simple control • Fieldbus connectivity • Simple to upgrade (add cylinders)

37 Contact Kyntronics 855-596-8765 www.kyntronics.com