APPLICATION DATA & CALCULATIONS Power Factor (Intensification) For air or hydraulically driven pumps, the power or intensification factor is determined by the drive piston(s) area divided by the fluid piston(s) area. This basically determines the output pressure and cycle rate capability of the pumping unit. The formula for calculating power factor is as follows: POWER FACTOR = Area of drive cylinder(s) Area of fluid piston(s) Example: A Posiratio machine with a 4" diameter air cylinder drive with a 30 mm diameter "A" pump and a 20 mm diameter "B" pump. Area of 4" air cylinder = 81.07 cm2 Area of 30 mm piston = 7.07 cm2 Area of 20 mm piston = 3.14 cm22 POWER FACTOR = POWER FACTOR =     7.9:1 If 100 psi air pressure is applied to the 4" air cylinder, 790 psi fluid outlet pressure can be obtained in a stalled condition. If 50 psi air pressure is applied, only 395 psi fluid outlet pressure can be obtained. The following is to be used as a guide only as the actual flow rate is dependent on a wide variety of factors including hose size, mixer size, fitting restrictions, injection block or gun employed, thixotropic characteristic of the material, heat, and any other factor that affects flow. Generally, the higher the power factor, the lower the volume output. Power Factor "Rule of Thumb" Chart Viscosity in Centipoise Approximate Power Factor Needed 50 to 500 1:1 500 to 1000 2:1 1,000 to 3,000 3:1 3,000 to 6,000 4:1 6,000 to 9,000 5:1 9,000 to 15,000 6:1 15,000 to 20,000 7:1 20,000 to 30,000 8:1 30,000 to 40,000 9:1 40,000 to 60,000 10:1 60,000 to 75,000 11:1 75,000 to 90,000 12:1 90,000 to 120,000 13:1 120,000 to 200,000 14:1 200,000 to 1,000,000 15:1 to 20:1 over 1,000,000 Consult Factory Air Cylinder Consumption This chart is used for calculating the air consumption of a cylinder(s) on a reciprocating application to determine the total volume of air required to meet a given cycle rate. The values shown are for 100 psi which is the maximum pressure we recommend for operating the cylinder(s). CYLINDER   AREA OF CYLINDER   SCFM SIZE (I.D.)   (sq. in)   (sq. cm)   (per 1" stroke at 100 psi) 1"   0.785   5.07   0.0035 2"   3.142   20.27   0.0142 2 1/2"   4.909   31.67   0.0223 3"   7.069   45.61   0.0319 4"   12.566   81.08   0.0566 6"   28.274   182.43   0.128 8"   50.266   324.31   0.222 10"   78.54   506.74   0.354 12"   113.098   729.71   0.512 Example: Total air consumption of a 6" diameter air cylinder with a 6" stroke operating at 10 cycles per minute (20 strokes per minute): 6" Stroke x 0. 128 SCFM/I" Stroke = 0.768 SUM 0.768 SCFM/Stroke x 20 Strokes/Min = 15.36 SCFM Note: To calculate total cylinder air consumption, both the forward and retract length of stroke need to be considered. Thus a 6" stroke air cylinder can travel a full 6" in each direction for a total of 12" of travel using 1.536 SCFM of air per cycle. To determine actual power factor requirements for a specific flow rate, tests can be run at Liquid Control's Application Laboratory with the specific material to be dispensed. Ratio of "A" to "B" The mix ratio of a two (2) component thermoset resin system is generally given as either volume ratio or weight ratio. Since all meter, mix and dispense machines use volumetric displacement, it is important to understand the difference between these and how to convert from one to the other. The following formula can be used when the density or specific gravity of both the "A" and "B" components are known and only one of the ratios: Example: Weight Ratio Volume Ratio = Specific Gravity "A" Specific Gravity "B" A material has a weight ratio of 10: 1, the "A" material has a specific gravity of 1.20 and the "B" material has a specific gravity of 1.00. To calculate volume ratio: 10:1 Volume Ratio = 1.20 1.00 Volume Ratio = 10 1.20 Volume Ratio = 8.33:1 Typically the wider the ratio of "A" to ''B'' (e.g. 20: 1, 50: 1, I 00: 1), the more critical the design of the meter, mix and dispense machine. Not only do the metering pumps require more precise volumetric displacement but the selection of the injection block or dispense gun and mixer is equally as important. Closer mix ratios (eg. P 1, 2-1, 5- 1) will normally result in the simplest machine design. Posiload Pump Sizing for Specific Ratios To calculate the size of either the "A" or "B" pump for a fixed-ratio meter, mix and dispense machine, when the volume ratio is known along with one of the pump sizes, the following formulas can be used: or Example: 1) What size catalyst pump (B) is required for a volume ratio of 10: 1 with a 40 mm resin pump (A)? 2) What size resin pump (A) is required for a volume ratio of 2.5:1 with a 15 mm catalyst pump (13)? Shot Capability of Standard Posiload® Pumps Pump Size* Maximum Shot (100%) Minimum Shot (15%) 10 mm 5.98 cc's 0.90 cc's 15 mm 13.47 cc's 2.02 cc's 20 mm 23.94 cc's 3.59 cc's 25 mm 37.40 cc's 5.61 cc's 30 mm 53.86 cc's 8.08 cc's 35 mm 73.31 cc's 11.00 cc's 40 mm 95.75 cc's 14.36 cc's 45 mm 121.19 cc's 18.18 cc's 50 mm 149.62 cc's 22.44 cc's 55 mm 181.04 cc's 27.16 cc's 60 mm 215.45 cc's 32.32 cc's 70 mm 293.25 cc's 43.99 cc's 80 mm 383.02 cc's 57.45 cc's 90 mm 484.76 cc's 72.71 cc's 100 mm 598.47 cc's 89.77 cc's Special size pumps from 10 mm through 100 mm can be machined for specific shot requirements. Volumetric Content and Ratios of Standard Material Hoses Includes nylon high-pressure and teflon-lined, stainless steel braided hose. The volumetric content of each size hose per lineal foot is provided in columns 3 and 4 in cubic inches (in3) and cubic centimeters (cc's). To determine the volumetric ratio of two equal length hoses, first locate one hose size in row I and the other hose size in column 1. At the point on the chart where these two hose sizes intersect, the volumetric ratio is given. (e.g. If "A" hose is 0.75" I.D. and the "B" hose is 0.375" I.D., the volumetric ratio between the two is 4.00:1 if they are of equal length.) HOSE SIZE TYPE OF HOSE VOLUMETRIC CONTENT 0.125" 0.187" 0.250" 0.312" 0.375" 0.406" 0.500" 0.750" 0.875" 1.000" in3/ft cc's/ft 0.125" (3/16) Teflon /SS 0.147 2.414 1 2.24 4.00 6.23 9.00 10.55 16.00 36.00 49.00 64.00 0.187" (3/16) (1/4) Nylon or Teflon /SS 0.330 5.402 - 1 1.79 2.78 4.02 4.71 7.15 16.08 21.89 28.6 0.250" (1/4) Nylon 0.589 9.655 - - 1 1.56 2.25 2.64 4.00 9.00 12.25 16.00 0.312" (3/8) Teflon /SS 0.917 15.037 - - - 1 1.44 1.69 2.57 5.78 7.87 10.27 0.375" (3/8) Nylon 1.325 21.723 - - - - 1 1.17 1.78 4.00 5.44 7.11 0.406" (1/2) Teflon /SS 1.554 25.463 - - - - - 1 1.52 3.41 4.64 6.07 0.500" (1/2) Nylon 2.356 38.618 - - - - - - 1 2.25 3.06 4.00 0.625" (3/4) Teflon /SS 3.682 60.341 - - - - - - - 1.44 1.96 2.56 0.750" (3/4) Nylon 5.301 86.891 - - - - - - - 1 1.36 1.78 0.875" (1) Teflon /SS 7.216 118.268 - - - - - - - - 1 1.31 1.000" Nylon 9.425 154.472 - - - - - - - - - 1 Note: The actual I.D.s of most Teflon/SS hoses is smaller than the hose designation. (e.g. 1/2" Teflon/SS hose has an I.D. of 0.406".) Generally, when designing a two-component meter, mix and dispense system, the volumetric ratios of the hoses should be close to the actual ratio of the resin system being dispensed assuming the "A" and "B" materials are of equal or close viscosity When there are wide differences in viscosity of the two materials, then flow rate and pressure drop have to be taken into consideration and the hoses sized accordingly.   Applications |  Products |  About Us |  Contact Us |  Request Information