ELECTRONIC PRESSURE MEASUREMENT For Mobile Hydraulics Industries ELIMINATING WEAK LINKS: How a Pressure Sensor Can
You know the old cliché: a chain is only as strong as its weakest link. Likewise, your equipment is only as good as each of its components. Choose Equipment Reliability... Every year, your customers must overcome a number of obstacles that threaten their operations: increasing control the weather, but you can help them by ensuring the reliability of your equipment.
Monitoring = Safe and Efficient Operation 3UHVVXUH VHQVRUV SOD\ DQ LPSRUWDQW UROH LQ WKH VDIH DQG HIÀFLHQW RSHUDWLRQ RI D ZLGH UDQJH RI PRELOH K\GUDXOLF equipment. They monitor a variety of functions, such as controlling operating pressure, load pressure, brake SUHVVXUH YDOYH SUHVVXUH ÀOWHUV ÁRZ UDWHV DQG ÁXLG OHYHOV Steering system ECU Electronic control unit Combustion engine Cooling system Main hydraulics Suspension system Hydraulic traction drive Brake safety CRITICAL TO FUNCTION (CTF) Measure pressure to control critical systems CRITICAL TO SAFETY (CTS) Measure pressure to provide warning of unsafe conditions BASIC MONITORING Measure pressure to ensure consistent performance Call 855-362-9452 or visit www.wika-sensors.com 1
True Cost of Failure: Mining one machine affects the rest of production. 1 One of your excavators breaks down... 3 Dozer and its operator stop working... 2 Call 855-362-9452 or visit www.wika-sensors.com
2 4 trucks and their drivers stop working... 5 4 Your customer demands an explanation You lose tens of thousands of dollars per hour Call 855-362-9452 or visit www.wika-sensors.com 3
4 Call 855-362-9452 or visit www.wika-sensors.com
Selecting a Sensor: Mining Shock and Vibration Shock and vibration can eat away at a pressure transmitter. Having a sensor that cannot withstand these forces could lead to unnecessary downtime. Electrical Interference EMI/RFI interference on a mining site, or on any site, can cause signal instability and inaccuracy in the pressure transmitter. Temperature Equipment using mobile hydraulic systems are typically temperature changes affect pressure transmitters as they do any electronics. Water Ingress can weather the high pressures and temperatures that are present during a high pressure wash down. Not to mention being able to stop water from entering the unit in all kinds of wet environments. Call 855-362-9452 or visit www.wika-sensors.com 5
True Cost of Failure: Construction Pressure transmitters help indicate that the application is within safe operating parameters. OSHA found that an accident can cost your company +$1,000,000 1 $7,000 1 Without Lost Work Day $28,000 1 With Lost Work Day $910,000 1 With Occupational Death 6 Call 855-362-9452 or visit www.wika-sensors.com
Down Machine $225/hr. 2 equipment rental cost alone $152,000 1 Indirect Costs In addition to personal injury costs, an accident affects production. These indirect costs can include schedule delays, repairs to damaged property, maintaining insurance coverage, and added administrative time, not to mention losing the trust of your most valuable customers. 1 OSHA average costs, includes both direct and indirect costs, excludes property damage. 2 WIKA industry research Call 855-362-9452 or visit www.wika-sensors.com 7
8 Call 855-362-9452 or visit www.wika-sensors.com
Selecting a Sensor: Construction Long-Term Stability The performance of a transmitter on day one is obviously essential, but its performance in year two, three and beyond is even more important. Shock and Vibration Is this a pressure transmitter that is going to be able to withstand the shocks and vibrations that are commonly present in a construction site? What about internal stresses such as changing loads and cavitation? Pressure Spikes You can have huge pressure spikes when you open and propagated waves of pressure that come back and hit the pressure sensor. Your sensor needs to be able to withstand these variations. Call 855-362-9452 or visit www.wika-sensors.com 9
True Cost of Failure: Agriculture Nutrient inputs are responsible for between 30-50% of crop yield 1... properly, then you can end up applying too much or too little material in a certain area... Resulting in the decreasing your crop yield. 1 http://www.ipni.net/ppiweb/ppinews.nsf/0/7de814bec3a5a6ef85256bd80067b43c/$file/crop%20yield.pdf 2 Industry studies 10 Call 855-362-9452 or visit www.wika-sensors.com
Selecting a Sensor: Agriculture Shock and Vibration Something as simple as a running engine can actually shake apart the sensor over time. You need a sensor Down machine cost = $7,000/hr. in rental cost alone. 2 Chemical Compatibility You want to make sure the sensor is compatible with the material your customer will be applying. Chemicals and Survive the Environment You need a pressure sensor that can survive the environment in which your equipment is used. If your unit is unable to withstand the elements such as torrential rainfall then water will get into the sensor. This may disrupt the electronics and skew the output. Call 855-362-9452 or visit www.wika-sensors.com 11
Why WIKA? At WIKA, we maintain control over every facet of our manufacturing, including making our own thin film sensor. This way, we can ensure our products give you the durability and reliability you and your customers demand. It s all a part of who we are at WIKA. We build it WIKA tough So you never have to apologize to a customer with a machine down. 12 Call 855-362-9452 or visit www.wika-sensors.com
From design to delivery to after-sales support, we ve structured ourselves to ensure you get the most efficient use of our products as possible. Collaborative Design Real-World Testing Customization Supply Chain Customer Care Value Innovation Workshop, we bring our engineers together with the engineers of key industry leaders to develop new, game-changing products. than 80 different tests including mechanical, environmental, and electrical tests to make sure our products can withstand your real-world environment. We can custom as signal output, pressure range, connections, and special design features to make sure you have the right product application. your company to choreograph logistics that reduce order and accommodate your needs. We provide the support you need to ensure you have products. Call 855-362-9452 or visit www.wika-sensors.com 13
Every Product is a Promise is a typical German trait, and we bring this scrutiny to every phase from design to process development and Innovative Product Design Quality Materials High Degree Process Control Rigorous Testing Real-World Results products, we can ensure you quality product with the manufacturer, customizable product We can also work with you and your team to help your product innovations 14 Call 855-362-9452 or visit www.wika-sensors.com
We Do Things Differently We believe that all relevant processes and technologies must be under our control. For instance, we make our own sensors to ensure we deliver reliable products. Sensors are at the heart of your monitoring device. While others may outsource this function to avoid the millions in capital expenditures, we refuse to relinquish control of something so important. By manufacturing our own sensors, we help decrease defect rates and improve durability and quality. Call 855-362-9452 or visit www.wika-sensors.com 15
WIKA Real-World Testing in all real-life conditions. Putting them through one test after another helps ensure they perform in an array of reallife conditions, not just one or a few. Batch of 10 Electrical Sensors Tests to ensure reliability and functionality 20 Mechanical Tests Such as Connector Accuracy, Housing Stability and Impact Resistance Tests to ensure reliability and functionality 50 Environmental Tests Such as Continuous Shocks, Ice Water, Vibration, Resistance to Chemicals and High Pressure 10 Electrical Tests Such as Overvoltage Resistance, Load Dump and Radiates Field 16 Call 855-362-9452 or visit www.wika-sensors.com
The result is a better product to handle the rigors of mobile hydraulics applications... Call 855-362-9452 or visit www.wika-sensors.com 17
MH-2 Mobile Hydraulic Pressure Transmitter plastic body, with a metal liner for EMI/ RFI protection. Welded sensor cell provides a leakfree seal that eliminates the need for additional soft-sealing materials. EMI properties in accordance with EN 61326 offer consistent operation even when interference. technology provides in applications producing frequent pressure cycles. Cable version provides environmental protection to IP 69K for resistance to high-pressure steam wash-down cleaning procedures. Cavitation Dampening System protects unit from pressure spikes and cavitation. including special pressure additional minimum quantity requirements and at a very low set-up cost. 18 Call 855-362-9452 or visit www.wika-sensors.com
MH-1 Pressure Transmitter spikes makes the MH-1 one of the most durable, accurate pressure transmitters available today. Its allstainless steel body and bullet-proof construction make the MH-1 suitable for the most severe environments. provide mechanical protection against system damaged. eliminates need for additional softsealing materials that may deteriorate over time. CDS system includes an arc eroded pressure channel for additional protection against pressure spikes and pulsations. Sputtered technology provides applications producing frequent pressure cycles. Provides ingress protection from IP 65 Call 855-362-9452 or visit www.wika-sensors.com 19
MHC-1 Pressure Transmitter an instrument concept that has been designed and tested for the severe operating conditions of mobile or J1939 protocol. * CANopen is a Community Trademark of CAN in Automation. or J1939 protocol. Version with integrated Y-connector offers easy and secure installation. High EMC protection shields unit from electrical interference. Offers IP 6K9K ingress protection. 20 Call 855-362-9452 or visit www.wika-sensors.com
MHS-1 Pressure Transmitter error of the safety-critical load monitoring system can be detected by monitoring the dual pressure sensors in reduces the probability of a dangerous failure and increases process security, not to mention reducing the cost of buying two individual sensors. Channel 1 can be a pressure sensor with proportional electrical output signal and Channel Cost effective mechanical and electrical installation costs are lower than installing two individual pressure sensors. Hermetically-sealed, welded, its sputtered Wheatstone bridge offers long-term stability in applications with high dynamic load changes. pressure spikes. Robust stainless steel housing and the IP 69K high pressure steam washdown rated electrical connection are designed conditions. and cavitation damping system integral to the process connection pressure sensor failure. Call 855-362-9452 or visit www.wika-sensors.com 21
We Make It WIKA Tough... So You Never Have To Say You re Sorry. No one want to receive a phone call from a customer with a machine down. So, why chose a sensor from a general industrial catalog when you have a mission-critical application? To learn more about how we have designed and tested our pressure sensors to withstand the real-world conditions your equipment faces, see our video at WIKA-Sensors.com. WIKA Instrument, LP B031-0000 06/13 WIKA