Industrial Automation Magazine India

Hybrid systems are becoming more common

Published on : Wednesday 03-03-2021

Sureshbabu Chigurupalli, Unit Head – Plant Operations at Balasore Alloys Limited.

Traditionally fluid Power played an important role in automation. Has electrical actuation now taken over?
Well, it depends. There is no easy answer. It all depends on the system design and evaluation of performance, cost of the components, system costs, and performance. Precision, speed and safety are the primary considerations. 
 
A fluid-powered actuator's functionality has an advantage over the electric actuator in its capacity to provide a simple fail to safe position function. The diaphragm and cylinder of a fluid-power actuator opposed by spring can move the valve to an open or closed position on the loss of fluid power. For a process shutdown, the fluid-power actuator is the traditional choice.
 
In contrast to fluid power actuators, electric actuators provide precise control and positioning. Low operation cost helps versatile machines to flexible processes. They are most economical when deployed on a moderate scale. 
 
In an era of digitalisation, electrical actuators' application focuses more on intelligent devices, Smart processes. Fluid power actuators are significant in sturdy applications.
 
What are the advantages Fluid Power still offers vis-à-vis electromechanical drives?
A: Fluid Power shares many benefits. These include:
• High horsepower-to-weight ratio 
• Safety in hazardous environments because they are inherently spark-free and can tolerate high temperatures
• Force or torque can be held constant — this is unique to fluid power transmission
• High torque at low speed — unlike electric motors, fluid powered motors can produce high torque while operating at low rotational speeds. Some fluid power motors can even maintain torque at zero rates without overheating
• With minimal power loss over long distances can transmit fluid Power through complex machine configurations.
• Multi-functional control — the single system can power many actuators 
• Elimination of complicated mechanical trains of gears, chains, belts, cams, and linkages
• Instantly operation can be reversed, and
Fluid power actuators have a unique choice for lifting tools, crushing, pressing, digging, and excavations due to high torque and speed regulations requirements. 
 
Large vehicles and the automotive industry have accounted for much interest in hydraulics. Will the upsurge of electrical vehicles sound a death knell for hydraulics?
Governments worldwide are putting pressure on vehicle manufacturers to reduce carbon emissions caused by diesel fuel combustion and tackle greenhouse gas emissions, in turn, pushing them to invest in developing electric trucks (e-trucks). 
 
Market research valued the electric truck market at USD 19.80 billion in 2020 and expected to register a CAGR of 14-15% during the forecast period (2021-2026).
 
Global demand for a cleaner environment and low-emission zones drive fleets to replace diesel trucks with EV options. India is among the fastest-growing economies and the third largest emitting country in the world. Petrol and diesel trucks are highly polluting. Stricter emission and fuel efficiency norms to deal with alarming pollution levels in most cities, vehicles with diesel engines may become a relic of the past by as early as the next decade.
 
The advantage of electrical actuators is that they are simple and low cost compared to the hydraulic system, which needs many more components. With increasing emphasis on reduced weight, electric actuators offer integrated designs where traditionally hydraulics or pneumatics have ruled the roost. Weak spots in the application, such as hoses and pumps, are eliminated by installing electric actuators. Easy installations, flexibility and energy efficiency, and compact design reduce trucks' overall weight, improving trucks' fuel efficiency.
 
It will be difficult to conclude at this moment that electrical actuators can replace hydraulics in totality, as efficiency is the prime factor. Design of pump capacities, battery uptime, sturdy applications where more improvements expected.
 
What are the new trends that hold promise for hydraulics and pneumatics in the digital era?
There are some vile areas where Fluid Power has traditionally been a superior choice over electric power.  Fluid power system designs are more complex and occupy space. New trends are more focusing on Miniaturisation, compact and straightforward designs. For instance, hydraulic pumps with electric drives are extremely precise and highly efficient, valves with embedded intelligence provide unprecedented accuracy and performance, and hydraulic hoses predict when they will fail. Hybrid systems that mix hydraulics and electronics are becoming more common. More research and innovations are happening on high performance, compact envelope, and customisation. These are just a few examples of next-generation fluid-power technology. Smaller, smarter, and more efficient is a trend.
 
How relevant is Fluid Power in process industries today?
Fluid power controls were more rugged and reliable. Fluid power systems are widely used when heavy force or torque is involved, such as lifting loads weighing several tonnes, crushing or pressing strong materials like rock and solid metal, and digging, lifting, and moving large amounts of earth. Fluid power technology is a preferred solution to heavy-duty applications where high power is required, whilst pneumatic technology is chosen for lightweight, high speed and comparatively low-cost applications. The latter also offers benefits in clean environments such as the food or electronics sectors. Although pneumatics can transmit high force and torque, it is extensively used for fast-moving, repetitive applications, such as pick-and-place operations, gripping, and repetitive gripping or stamping.
 
Are hydraulic and pneumatic devices compatible and in step with digital technologies and integrate with IIoT seamlessly?
Predictive diagnostics software is a key player in IIoT-integration. Smart sensors and intelligence built-in diagnostic capabilities help monitor temperature, voltage, current, and even cycle counts. The massive amount of data these sensors produce creates an equally tremendous opportunity to transform how one operates and maintains industrial equipment. Predictive and preventive maintenance programs are essential to efficiently manage equipment life cycles and maximise the overall equipment effectiveness (OEE) and increase return on investment. Using data from IIoT sensors, technicians can predict accurate information on deteriorating components and take corrective steps such as modulating stroke speed to enhance life. The value of any IIoT solution is directly proportional to its interoperability. Open exchange-based architecture that enables interoperability with third-party products, applications and platforms is essential. Data security, sensing, safety and ease of use, flexibility, and energy efficiency are critical in integration. 
 
Sureshbabu Chigurupalli is Plant Head – Balasore Alloys Limited, Odisha. Sureshbabu is leading and managing all plant operations with effective utilisation of all resources and implementing industry best practices such as TPM, Six Sigma, Lean Management and other Business Excellence initiatives that contribute to improve productivity and efficiency. He has exhibited leadership in closely collaborating with numerous Japanese Consultants for implementing TPM to enhance overall plant effectiveness.
 
A B.Tech in Instrumentation from Andhra University (1994), Sureshbabu is an enterprising leader and planner with a strong record of contributions in streamlining operations, invigorating businesses, heightening productivity, systems and procedures. He has achievement-driven professional experience in spearheading entire unit/plant operations to maintain continuity and match organisational goals through supervising Operations, Quality Control, Production Goals, Automation, Maintenance, Process Improvements, Safety Guidelines, Manpower Development, New Policy/Procedure Guidelines, Resource Allocation and Cost Optimisations.