Air Over Oil Cylinders Archives - HyperCyl

Tag Archive: Air Over Oil Cylinders

  1. How To: Determine the Appropriate Technology for High Force/High Speed Applications

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    Flexibility, performance, capital and operating costs have always been key factors in today’s expanding manufacturing marketplace. For decades hydraulics and mechanical presses were the only options for high-speed, high-force assembly and forming applications. More recently hydra-pneumatics and servo-based systems have emerged as viable low-cost alternatives. So which technology is best suited for a specific application? The following topics can serve as a guideline towards the correct usage.
    Aries Engineering is the only manufacturer Headquartered and Manufactured in North America offering both servo driven and hydra-pneumatic solutions.

    Servo-Based Technology – HyperCyl-EMA

    Capability: Provides exceptional control over force, speed, and distance characteristics. Requires the use of a full PLC/PC based electrical panel and 230V/460V. Best used for push-to-distance or push-to-force applications, push/pull applications and where Extreme repeatability is essential. Signature analysis, data logging, part history, trending and root cause analysis options are also available for added functionality and tracking.

    Reliability: Servo technologies are inherently capable and sizing them appropriately is crucial. Expected lifetime is from 3 Years to 5 Years, configured for any application. Long-Term Reliability coincides with maintenance schedules.

    Speed: Up to 16.00 in/sec with an extremely high rate of repeatability. Requires a deceleration setting before Contact and Home to maximize tooling and screw life.

    Forces: 1-10 Ton in Ball Screw configurations (BS1 & BS2) with a medium dynamic load rating; 1-25 Tons in the Roller Screw configuration with a high dynamic load rating.

    Maintenance: 3/6-month lube schedule & periodic belt tension check dependent on usage and environment.

    Cost: Can be higher initial cost than comparable Hydraulics. Energy efficiency and ROI achieved with minimal downtime, low noise pollution, rapid setting changes without involving tooling, ZERO environmental pollution, comparable energy usage to hydraulics without the mess.

    Hydra-Pneumatic Cylinders – HyperCyl

    Capability: Utilizing 2 pneumatic valves for operation and a FRL greatly reduces start up time. Cylinders are available in 5 design configurations and 11 standard sizes. Best used for; crimping, dimpling, peening, swaging, inserting, clinching, pressing, staking, piercing, punching, marking, bending, and forming. When coupled with the IntelliCyl option, (load cell and LVLT) force distance monitoring is available.

    Reliability: (MTBS) Mean time between service interval of approximately 4-5 million cycles because down time is not an option. LIFETIME warranty on all HPI – HPS – HZ – HZS – HPT cylinders, 1-Ton through 200-Ton.

    Speed: Fast Approach speeds similar to that of a pneumatic cylinder (6 in/sec – 10 in/sec) and High-Pressure speeds similar to that of hydraulic cylinders (1.0 in/sec – 2.0 in/sec).

    Forces: 1-200 tons of output force using 30-100 PSI shop air.

    Maintenance: 20 million cycles before seals require replacement. Field serviceable by maintenance techs and 24-hour HyperCyl assistance is available. Periodic maintenance depends on application and environment.

    Cost: More expensive than Pneumatic cylinders but offers the same clean, quiet & self-contained operation. Less expensive than hydraulic and mechanical systems for both short & long-term investments.

    Additional Products:

    HyperView Press – SigPOD
    IntelliCyl – load cell & linear transducer
    HyperPress-C Frame, H Frame, CGB Frame
    Equalizing/ Non-Equalizing Units Pneumatic
    Mechanical Rod Locks

    Industries Served:

    HyperCyl Manufacturing Industries Served – Automotive, DoD, Lawn & Garden, Appliance, HVAC, Food & Beverage Packaging, Destructive Testing, ATV/Off-Road

    HyperCyl-EMA Industries Served – Medical Device Manufacturing, Aerospace, Automotive, Food Product Manufacturing, Clean Room Environments, Lab Testing

    To learn more about our product solutions and how they can benefit your assembly or forming application, contact us today. To discuss your application requirements with one of our experts, request a quote.

  2. Can HyperCyl meet your application needs?

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    HyperCyl’s products are designed to enable clean, quiet, and precise operations with minimal maintenance requirements. Our diverse product portfolio supports a wide range of industries and applications.


    Aries Engineering/HyperCyl is a Michigan-based company specializing in the fabrication of cylinders, presses, and other products for assembly and forming applications in the industrial automation, manufacturing, commercial, and defense industries. Our versatile products cover virtually all segments of industrial production, from medical and electronic device manufacturing to heavy industrial piercing and forming, including:

    • Automotive (engine/transmission, suspension, body)
    • Medical devices (clean-room)
    • Semiconductors (clean-room)
    • Electronic devices
    • Appliances (washer, dryer, etc.)
    • Munitions (bullet manufacture, warhead seal & contain systems)
    • Office furniture
    • Coining
    • Hemming

    Meeting Your Application Needs

    Whether you need a simple press, high-precision actuator, or fully customized turnkey system, HyperCyl has the manufacturing expertise and problem-solving skills to provide unique solutions for a range of assembly and forming challenges. Our press systems include C-frame, H-frame, and CBG-frame options, and we also offer HyperPierce units available in both equalizing and non-equalizing designs.

    HyperCyl cylinders are clean, quiet, and reliable self-contained power sources with versatile designs capable of accommodating various industrial operation requirements.

    In addition to our standard product line, we also accommodate special requests, and can tailor our cylinder and actuator designs around the customer’s specific production requirements with reasonable turnaround times and prices.

    Quality You Can Expect

    When you choose a HyperCyl for your operation, you can expect:

    • The ability to separately regulate the approach and power strokes, providing enhanced control over the process and eliminating the need for cylinder reconfiguration
    • Increased retract force versus competition, allowing for heavier tooling
    • No stored energy hazards as the cylinders do not use mechanical springs to assist the pistons (competition does use internal springs)
    • Increased value over alternative cylinder options, including multi-stage air cylinders and hydraulic cylinders and power units
    • Limited lifetime warranty

    To learn more about our product solutions and how they can benefit your assembly or forming application, contact us today. To discuss your application requirements with one of our experts, request a quote.

  3. Why Use Air Over Oil Cylinders?

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    HPS (Tandem, minimal profile) Air over oil cylinders are pneumatic cylinders designed to produce greater force than standard pneumatic cylinders of the same bore size. They incorporate both oil and air within the mechanism, creating a hybrid pneumatic-hydraulic cylinder that intensifies the amount of force generated by compressed air input.

    HyperCyl takes the innovative design of hybrid air over oil cylinders to the next level with our patented rod and piston mechanism. Unlike other designs, our cylinders do not use an external oil reservoir. Instead, the oil reservoir is completely sealed and incorporated into the cylinder itself. Our air over oil cylinders uses compressed air on the piston to exert force within a sealed hydraulic chamber by pneumatically driving a rod into the oil reservoir, which is situated behind the work piston.

    Why Use Air Over Oil Cylinders?

    Air over oil cylinders offer a host of unique advantages over more traditional pneumatic systems. Since compressed air is ubiquitous in virtually every industrial setting, it offers a convenient source of clean power that can easily be intensified using HyperCyl’s air over oil cylinders.

    Our state-of-the-art air over oil cylinder design offers a low-cost, highly efficient means of converting compressed air to smooth fluid force. HyperCyl’s air over oil cylinders only use 25% – 30% of compressed air when compared with multi-piston pneumatic cylinders for the same operation.

    While many companies are phasing out hydraulic power units and cylinders, the HyperCyl air over oil cylinders offer a cost-effective solution for facilities that want the power of a hydraulic system in a smaller package. Our air over oil intensifier units can provide up to 200 tons of force while using significantly less space than traditional hydraulic systems. The smaller size of our air over oil cylinders allows for reduced bore size compared to standard multi-stage pneumatic cylinders.

    Our air over oil cylinders make no more sound than a standard pneumatic cylinder. Since there is no power unit like hydraulics, you enjoy less noise, less heat generation, and no continuously running motor. Energy is needed only while HyperCyl is moving; at rest zero noise and zero energy is realized. To suit your specific needs, we offer six models of air over oil intensifier cylinders suitable for a broad variety of industries and applications. In addition, we are pleased to work with you to create custom stroke cylinders quickly and efficiently, within your budget.

    Partnering With HyperCyl for Air Over Oil Cylinders

    For more than 25 years, HyperCyl has been a leading expert in the design and manufacture of air over oil, or hydra-pneumatic, cylinders. Our extensive expertise extends to servo-controlled actuators, assembly cells, and presses using our cutting-edge cylinder technology. As a privately-owned company based out of Dundee, Michigan, we are proud to produce our products in America.

    We are dedicated to helping our customers find the perfect motion solutions for their particular needs. Our seasoned experts will work closely with you to determine the appropriate force and stroke requirements for optimal power and efficiency. Each of our air-over-oil cylinders offers unique features to enhance your operations, soft initial part contact and enhanced energy efficiency. The pressure stroke of the cylinder can be regulated separately from the approach stroke, allowing you to fully tailor your force and energy usage for optimal cost savings.

    At HyperCyl, we offer a variety of triggering mechanisms for high-pressure actuation, without the need for cylinder alterations. This mechanism can be triggered based on a pressure threshold (ELT sensor), specified stroke distance (LVDT), or a simple proximity sensor. Other standard features of our air over oil cylinders include:

    • Complete air/oil separation
    • Wear bands on internal pistons for increased life
    • Variable operating positions or attitudes
    • No external oil reservoir
    • Up to 200 tons linear output force
    • Three primary moving components
    • NFPA medium-duty mounting
    • Tie rods with 100,000 psi tensile-strength
    • Operation and maintenance manual
    • Heavy-duty construction for long service life
    • 4.5 million MTBF (mean time before failure)
    • 20 million cycle service life
    • Accessories include gauge kits, sensors, total stroke limiters, alignment couplers, rod locks, and more
    • HyperCyl’s “IntelliCyl” package offers in-process validation of each part thereby dramatically reducing part-nonconformance, scrap rates, and check QTY of fixtures involved
    • Limited Lifetime warranty for cylinder materials and workmanship

    Superior Quality and Exceptional Workmanship by HyperCyl

    Since 1994, HyperCyl has been providing innovative solutions to some of the most challenging motion problems. Our years of experience and commitment to quality have made us a leading provider of actuators and press systems for customers in almost any industry. We hold our products to the highest standard, consistent with the Buy American Act and Made in the USA requirements.

    To learn more about our extensive selection of air over oil cylinders and other actuation solutions, contact us today or request a quote.