Useful Knowledge Eight Tips for Fluid Technology

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Develop reliable, more efficient machines with our tips for hydraulics and pneumatics. Learn, for example, when to use piston instead of bladder accumulators, where to download free CAD data for pipe connection components, and how to make pneumatic control systems more compact.

Design Machines Energy-Efficiently

In machine construction, designs are often oversized by five to ten percent as a precaution. However, this causes machines to waste unnecessary energy. This can be avoided by 1. determining the actual requirements and 2. working with an open approach to technology. To determine requirements, questions such as the following are helpful: How much load is being moved? At what speed? How is power transmitted? What variations of machine and drive concepts exist? Which combinations are efficient? This systematic analysis—ideally using a morphological matrix—forms the basis for efficient solutions that are subsequently simulated in the CAD system. If loads of up to one ton need to be moved, electromechanical solutions are usually a good choice. Between two and four tons, it depends on the application. Above five tons, hydraulics are generally more efficient, even for stationary machines. The Hydraulics Initiative provides support and expertise for the use of hydraulics.

Prevent Seal Failure With FFKM

In the pharmaceutical, chemical, semiconductor, and energy industries, even a small leak can lead to production downtime, regulatory violations, or costly contamination. Seals in these environments face challenging conditions: exposure to aggressive chemicals, temperatures above 482°F, frequent cleaning cycles with steam, plasma, or solvents, vacuum and cleanroom requirements with zero tolerance for outgassing, as well as mechanical stress from pressure fluctuations, acidic gases, or HPHT conditions. Some companies in such high-stress environments use standard elastomers. However, this can result in frequent seal failures, unplanned downtime, regulatory risks, and high operational costs. A better alternative is to use seals made of perfluoroelastomers (FFKM), such as the Evolast seals from Angst+Pfister, produced in Italy and now part of a group-wide offering. They are characterized by chemical resistance, ranging from acids and bases to strong solvents. The seals are temperature-stable from 
–51°F to 644°F, suitable for cleanroom-compatible production with traceability, and compliant with FDA, USP Class VI, EU 1935/2004, NORSOK, NACE, ISO 23936/2. The manufacturer offers application-specific variants—from standard O-rings to custom-molded parts and plates.

Free CAD Data for Pipe Connection Components

Voss Fluid, a manufacturer of line and connection systems for mobile and stationary hydraulics, provides designers with an online CAD database on its website. This database offers permanent free access to high-quality CAD data for over 15,000 pipe connection components in more than 80 common 3D and 2D formats. The data can be directly integrated into the users' CAD systems. Users gain insights into all dimensions and technical data through the database. This allows designers to find the component that suits them using various search options. With the shopping cart function, they can save items and request a non-binding quote directly. A planned update for autumn 2025 will enhance the platform with new products, customs tariff numbers, material specifications, and a convenient size comparison feature using model dimensioning.

Compliant With the F-Gas Regulation And Practical: CO2 As A Refrigerant

Refrigerants not only ensure the necessary cooling performance in cooling and temperature control devices but also determine whether a device is environmentally friendly and complies with legal regulations. Among these requirements is the EU F-Gas Regulation 2024/573, which mandates that manufacturers and users within the European Union must ensure by the end of 2025 that the refrigerants used have a GWP (Global Warming Potential) value of no more than 150. Many device manufacturers are therefore switching to alternative refrigerants. But which refrigerant should be used? This warrants a closer look, as the GWP limit of 150 allows for some flexibility. SMC, for example, is gradually converting its cooling and temperature control devices to the refrigerant R744 (CO₂), which has a GWP value of only 1. The HRSC series will be the first to make the switch. Unlike most refrigerants, carbon dioxide is neither toxic nor flammable. Due to its properties, it meets the A1 classification according to the ASHRAE-34 standard. Devices equipped with this refrigerant can therefore also be transported by air. The non-flammability—a crucial property of CO₂—significantly increases application safety, for example, in the electronics or semiconductor industry. Additionally, the non-flammable devices offer greater flexibility regarding installation space.

Bladder or Piston Accumulator?

In gas bottle installations, both bladder and piston hydraulic accumulators are used. For external gas storage, the hydraulic accumulator should have identical connection cross-sections at the gas and hydraulic connections to allow unrestricted gas flow between the gas bottle and the accumulator. The gas bottle itself is equipped with a corresponding connection at one end and a gas filling valve at the other end. When designing a piston hydraulic accumulator, care must be taken to ensure that the piston does not hit during the operating cycle. On the other hand, bladder hydraulic accumulators should be dimensioned so that they are filled to a maximum of 75% to avoid overstretching the bladder. Additionally, for bladder hydraulic accumulators, a special transfer barrier tube is required at the gas end to prevent the bladder from being squeezed into the gas bottle line. However, this design limits gas flow due to the narrow neck of the transfer barrier tube. Due to these technical limitations, users often prefer piston hydraulic accumulators as they offer higher reliability and better flow conditions. In summary: For gas bottle installations, piston hydraulic accumulators are usually the first choice due to their robust construction and better hydraulic properties. Bladder hydraulic accumulators are only suitable under certain conditions and with appropriate protective measures.

Compressed Air Systems: How to Avoid And Eliminate Leaks

Compressed air leaks are a common and costly problem in industrial plants, often going unnoticed. Energy losses due to leakage can account for up to 30 percent of the energy consumption in a compressed air system. Regular inspections and maintenance enable the detection of leaks, improving efficiency and reducing waste. Routine system checks conducted quarterly or semi-annually allow leaks to be identified in often overlooked areas such as aging pipes, fittings, flanges, distributors, hoses, and couplings. Corroded pipes, worn connectors, or damaged hoses can lead to significant leakage, while improperly sized components further strain the system. Monitoring devices like flow and pressure sensors make leak detection more permanent and efficient. For example, the new M/80 inline flow sensor from Imi Norgren operates on the principle of thermal dispersion and reliably detects even small flow rates, which are typical of leaks. This enables quick action to minimize downtime.

Preventive maintenance is important: Regular inspection and cleaning of filters, dryers, and similar components prevent pressure drops due to contamination. Adhering to maintenance schedules and correctly sizing components are also crucial. Over- or undersized parts can lead to an inefficient system. Another option is shutting down temporarily unused parts of the piping system. Subsystems often remain pressurized even during extended periods of inactivity. By using shut-off or start-up/vent valves, these areas can be temporarily isolated, thereby reducing leaks and saving energy.

Proportional Pneumatics: Two Control Types, One Hardware

With the Open Frame Controller (OFC), Camozzi Automation has developed a modular, configurable control system that can function as a pressure, flow, or position controller. The highlight is the Twin-Control functionality, allowing the controller to switch between two control modes—for instance, from position to force control.

This allows a cylinder to be precisely positioned with just one 3/3-way proportional valve before seamlessly transitioning into a force-controlled pressing operation. Similarly, switching between flow rate control for speed regulation and pressure control for force adjustment is possible—without additional hardware.

The OFC uses two independently operating control loops. Switching is achieved through various interfaces such as switch inputs, IO-Link, or industrial fieldbuses (e.g., EtherCAT, Profinet). This saves space, reduces cycle times, and increases the flexibility of the application.

The Special-Application-Functions (SAFs) are also interesting. These firmware extensions are tailored specifically to user requirements. They enable individual mapping of internal control variables, diagnostic data, and control variables. Additionally, control parameters—such as P, I, or D components—can be adjusted during operation to dynamically respond to changing load situations.

The Twin-Control functionality of the Open Frame Controller combines dual functionality in a single component. For design and development, this means: less hardware, more flexibility.

This is how vacuum pumps stay cool when it gets hot outside

At higher ambient temperatures, the oil in vacuum pumps breaks down faster than in cooler environments. This means it needs to be replaced more frequently, increasing maintenance costs. In technical rooms with temperatures exceeding 104°F, vacuum pumps can even overheat and fail. The effectiveness of natural ventilation through vents and cooling openings varies depending on temperature and wind speed and is not always sufficient. Particularly in confined spaces, installing a fan system to divert warm air and draw in cool air is a highly effective way to keep the technical room cool. Thermal management solutions and an intelligent design of the technical room are other important factors: By venting the exhaust air from vacuum pumps out of the technical room, heat dissipation into the room can be reduced by up to 35 percent. Pay attention to the proper material selection for piping, as it can become hot. By installing retrofitting kits for heat recovery, available for certain vacuum pumps, up to 80 percent of the energy consumed by the vacuum pumps can be recovered and utilized. Additionally, a well-thought-out design of the technical room can help prevent overheating. For instance, ensuring sufficient spacing between pumps allows for adequate air circulation.

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