National Fluid Power Association - PowerPoint Presentation

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Slide1

National Fluid Power Association

www.nfpa.com

2016 Annual Report

on the U.S. Fluid Power Industry Slide2

Fluid power (hydraulics and pneumatics) is a workhorse of the U.S. economy. It is a cross-

cutting technology of choice for dozens of industries and hundreds of applications.

In 2016, the manufacture of fluid power components was a $19 billion industry.The U.S. fluid power industry is strongly competitive around the world, with 2016 exports valued at $5.5 billion.

It is estimated that 862 companies in the United States employ more than 67,149 people in the manufacture of fluid power components, representing an annual payroll of more than $4.3 billion. Fluid power has a significant downstream economic impact. Ten key industries that depend on fluid power are estimated to represent more than 23,200 companies in the United States, employing more than 778,056 people with an annual payroll of more than $49.5 billion.

Fluid power and the industries it serves depend on a highly-educated workforce. Investments

in new fluid power education and training resources are occurring and more 2-year and 4-year colleges are teaching fluid power. Executive Summary

© NFPA, 2016 Annual Report on the U.S. Fluid Power IndustrySlide3

Fluid power systems consume a significant portion of our nation’s energy. Existing technologies and

best practices have been shown to reduce energy use in fluid power systems, in some cases by up to

30% or more.Through the Technology Roadmap for the Fluid Power Industry, the industry is identifying and addressing key research challenges that will continue to meet the needs of its diverse customer base.

Fluid power has an active industry/academic coalition that focuses on these key research challenges. Recent breakthroughs have been made in increasing energy efficiency, increasing energy storage capabilities, and reducing the size of fluid power components and systems.Future directions of fluid power research will additionally focus on improving its reliability, building “smart” components and systems, and reducing its environmental impact.

A new effort to address the specific manufacturing needs of the fluid power industry has begun. This effort will seek to leverage several key manufacturing technologies to improve the production and

performance of fluid power components and systems. Executive Summary cont.

© NFPA, 2016 Annual Report on the U.S. Fluid Power IndustrySlide4

Enduring and Essential

Fluid power systems transmit more power in a smaller space than other forms of power

transmission, making it the cross-cutting technology of choice for dozens of industries and hundreds of applications.Advantages of

hydraulics include:High power to weight ratioHigh torque at low speedAbility to hold torque constantRuggedness and reliabilityAdvantages of pneumatics include:

Inexpensive and lightweightSimple control systems

Clean and non-reactive in magnetic environmentsSpeed and precisionMaking hydraulics essential for:Construction machinery

Agricultural machinery

Heavy trucks

Material handling machinery

Mining machinery

Oil and gas machinery

Metalworking machinery

Making

pneumatics

essential for:

Automotive manufacturing

Packaging machinery

Food processing machinery

Medical equipment

Semiconductor manufacturing

© NFPA, 2016 Annual Report on the U.S. Fluid Power IndustrySlide5

Industry Size

In 2016, the manufacture of fluid power components was a $19.0 billion business in the United States.

It was the second year of decline after five straight years of industry growth, but still remains 14.5% higher than its pre-recession high in 2008.

© NFPA, 2016 Annual Report on the U.S. Fluid Power IndustrySlide6

Industry Size

The manufacture of hydraulic products was a $14.2 billion business in 2016, 75% of the fluid power total.

The manufacture of pneumatic products was a $4.8 billion business in 2016, 25% of the fluid power total.

© NFPA, 2016 Annual Report on the U.S. Fluid Power IndustrySlide7

Exports

In 2016, the value of U.S. exports of fluid power was

$5.5 billion. Exports have increased 17% since the 2011, and are 62% higher than pre-recession high in 2008.

The top ten destinations for export growth over the last five years account for 48% of all U.S. fluid power exports.

© NFPA, 2016 Annual Report on the U.S. Fluid Power IndustrySlide8

Jobs & Economic Impact

Based on

2015 U.S. Census Bureau data, it can be estimated that 862 companies employ 67,149 people in the manufacture of fluid power pumps, motors, valves, cylinders, actuators, hoses, and fittings, with an annual

payroll of more than $4.3 billion.

© NFPA, 2016 Annual Report on the U.S. Fluid Power IndustrySlide9

Downstream Impact - Markets

Fluid power has a significant downstream economic impact. Dozens of U.S. industries depend on fluid power

technology for their operations and for the competitiveness of their products.Construction Machinery

Agricultural MachineryAutomotive (light trucks)Class 4-8 Trucks (vocational)Material Handling (conveying)Lawn and GardenTop

Hydraulic MarketsAutomotive (light trucks)

Food ProcessingMedical EquipmentClass 4-8 trucks (vocational)Packaging Machinery

Material Handling (conveying)

Top

Pneumatic

Markets

© NFPA, 2016 Annual Report on the U.S. Fluid Power IndustrySlide10

Downstream Impact - Jobs

Based on 2015 U.S. Census Bureau data, ten of these industries—construction machinery, oil and gas machinery, food product machinery, metalworking machinery, material handling equipment, packaging machinery,

automobile and light duty motor vehicles, heavy duty trucks, medical equipment, and other general purpose machinery—represent 23,200 companies in the United States, employing 778,056 people with an annual

payroll of more than $49.5 billion.

© NFPA, 2016 Annual Report on the U.S. Fluid Power IndustrySlide11

Education & Training

Fluid power and the industries it serves depend on a highly-educated workforce. Investments in new fluid

power education and training resources are occurring, and more 2-year and 4-year colleges are teaching fluid power. NFPA maintains a network of these colleges, and their regional distribution across the country is increasing.Number of 2-year and 4-year colleges in the NFPA

Educator Network

= 10 - 12

= 1 - 3

= 4- 6

= 7 - 9

© NFPA, 2016 Annual Report on the U.S. Fluid Power IndustrySlide12

Energy and Efficiency

Fluid power systems consume a significant portion of our nation’s energy, and well-designed and well-

maintained fluid power systems can be very energy efficient. Unfortunately, many working fluid power systems are not well designed nor well maintained. Many technologies and best practices exist to maximize the energy efficiency of fluid power systems, including:Several companies perform audits to identify and troubleshoot weaknesses in working fluid power systems. Data

provided by one these companies indicate that when these technologies and best practices are implemented, average energy savings are 31%, and the cost of implementation is recouped within 4-5 months.Hydraulic systems:Eliminating parasitic lossesEffective flow controlSmart use of accumulators

Pressure reducing valvesLoad sensing pumps

Pressure compensated pumpsServo valvesHydraulic power units vs. electric motorsPneumatic systems:Eliminating pressure drop

Repairing leaks

Reducing pressure

Evaluating plumbing and storage

Optimizing air blow

Employing intermediate bore-size cylinders

Correctly sizing all components

© NFPA, 2016 Annual Report on the U.S. Fluid Power IndustrySlide13

Technology Roadmap

NFPA’s Technology Roadmap for the Fluid Power Industry identifies the key research challenges that the

industry is addressing for fluid power to continue meeting the needs of its diverse customer base.Customer Drivers

Research ChallengesCustomer drivers are the business or technology objectives of fluid power customers. They help them serve the needs of their own customers, and are not necessarily connected to their use of fluid power.

Research challenges are the broad areas of attention that must be addressed if fluid power is to meet or better meet the customer

needs described by the drivers.Increasing the energy efficiency of fluid power components and systems

Improving the reliability of fluid power components and systems

(e.g., increasing up-time, reducing maintenance requirements, making

fluid power safe and easy to use)

Reducing the size of fluid power components and systems while

maintaining or increasing their power output

Building “smart” fluid power components and systems (i.e., ones that

perform self-diagnostics and troubleshooting and that integrate easily

with “plug and play” functionality)

Reducing the environmental impact of fluid power components and

systems (e.g., lowering noise, eliminating leaks)

Improving and applying the energy storage capabilities of fluid power

components and systems

Increased productivity and

performance

Increased availability/ up-time

Lower total cost and life cycle costs

Increased ease/predict-ability of

maintenance

© NFPA, 2016 Annual Report on the U.S. Fluid Power IndustrySlide14

Research & Development

The Center for Compact and Efficient Fluid Power (CCEFP) is a network of fluid power research laboratories,

academic faculty and graduate students at several U.S. universities. The CCEFP works with the fluid power industry to tackle the research challenges identified in NFPA’s Technology Roadmap for the fluid power Industry. Its research successes include:

High Efficiency ExcavatorThe use of individual pump displacement control to directly command hydraulic actuators has demonstrated 40% fuel savings on an excavator. Efforts are currently underway to

incorporate hybridization into the system for even greater fuel savings.

Strain Energy Accumulator

Free Piston Engine/Pump

Precise piston motion control is

necessary for reliable operation of a

free piston engine pump that can

directly convert liquid fuel combustion

into hydraulic power. The demonstration of this technology merges the engine

and pump into one compact assembly.

Increasing Energy Efficiency

Improving Energy Storage

Capabilities

Reducing the Size of

Systems

© NFPA, 2016 Annual Report on the U.S. Fluid Power Industry

Current accumulators use either

compressed gas or springs to store energy.

Conversely the CCEFP carbon nanotube

elastomeric accumulator safely stores

energy as strain. Energy savings greater

than 25% have been demonstrated

over existing pneumatic systems. Slide15

Manufacturing Roadmap

A second technology roadmap—this one focused on improvements in how fluid power components are

manufactured—was published in the past year. It reveals several cross-cutting themes that are specific to the fluid power industry, including the need for:High precision coupled with multiple product configurations and small orders sizes

Single piece flow (batch size of one)Increased production ratesQuality levels that are matched to requirements that reflect real world operationEnvironmentally friendly processesTo help address these themes, the Fluid Power Manufacturing Roadmap identifies specific research needs

associated with fluid power’s adoption of the following manufacturing technologies and processes:

CoatingsMicro-machiningComposites/engineered plasticsSintered metalsAdditive manufacturing

Batch-free heat treating

Robotics

Hybrid manufacturing

Metrology

In-process sensing, feedback, and control

© NFPA, 2016 Annual Report on the U.S. Fluid Power IndustrySlide16

National Fluid Power Association

www.nfpa.com

2016 Annual Report

on the U.S. Fluid Power Industry