How To: Determine the Appropriate Technology for High Force/High Speed Applications
Comments Off on How To: Determine the Appropriate Technology for High Force/High Speed ApplicationsFlexibility, 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.
In contrast to strictly pneumatic or strictly hydraulic cylinders, these hybrid cylinders rely on the surface area differential of an internal pneumatic piston-rod assembly to significantly increase the pressure of trapped oil above the work piston, to provide an intensified hydraulic cylinder output force. Initially, they function similarly to pneumatic, double-acting cylinders, extending and retracting to the workpiece with output forces typical of pneumatic cylinders. However, once in contact with the workpiece, a second pneumatically controlled cylinder section drives a rod into the oil section, sealing it off, and intensifying the internal pressure. The intensified oil pressure pushes against the work piston, producing an increased output thrust, typical of hydraulic cylinders.
Three major moving components
The full line (six series) of HyperCyl® hydra-pneumatic cylinders are designed for machine builders and OEMs to use in their own presses and automation, as well as for use in HyperCyl supplied presses. HyperCyl presses are available with “C” frames or “H” frames, unguided, two-column guided, or four-column guided upper bolsters, and bench-mounted, pedestal, or machine base configurations. Due to their modular design, machine designers can choose a simple frame and drive unit design that facilitates integration into a larger assembly process, or a turnkey design that incorporates automation technology, controls, and more.