Comments Off on HyperCyl Case Study: Clinch Studs & Clinch Nuts
A major U.S. manufacturer of automotive components contacted HyperCyl® to increase quality & speed of their finished products and free up floor space for a new assembly line. The OEM was experiencing persistent assembly interruptions due to their hydraulic Clinch Nut & Clinch Stud operations inability to monitor & relay actual insertion forces & distances. To make room for a new product launch, removing the noisy pumps, balky accumulator tanks and high-heat motors used with antiquated hydraulics was essential.
HyperCyl® provided a clean, fast and data-centric solution removing all hydraulic units from the line and replacing with Hydra-Pneumatic cylinders operated by simple pneumatic valves. Each location now includes the IntelliCyl® integral LVDT and Load Cell options to monitor force/distance per cycle. The HyperCyl® solution actively measures the Stud & Nut insertion depth by establishing a series of “windows” around critical points of the operation. Namely the part stack-up (part contact) and final depth to go along with force is being monitoring throughout the process. IntelliCyl® provided
key measurements of the operation ultimately reducing in-process part non-conformance to near-zero. Instead of learning and managing dozens of different types of systems, plant personnel can now focus on making quality and productivity improvements on the assembly line.
We can also help you improve the quality of your product while reducing your costs and allowing your business to maintain the competitive edge. HyperCyl offers Hydra-Pneumatic and Servo Actuator solutions, applications engineering, testing, tech-support and the best warranty in the industry! To find out more how we can help meet your application needs, email [email protected].
Comments Off on HyperCyl Case Study: Removing Hydraulics from the Equation for Assembly
A major U.S manufacturer of braking and suspension components contacted HyperCyl® to increase quality of their finished products and free up floor space for a new assembly line. The OEM was experiencing persistent assembly interruptions due to their Hydraulic Dial Tables’ inability to monitor & relay actual insertion forces & distances. Additional floor space was also necessary to make room for a new product assembly line, so removing the noisy pumps, balky accumulator tanks, high-heat motors and leaking hydraulic lines associated with the antiquated hydraulics was essential.
HyperCyl® retrofitted the entire Dial Table, removing all hydraulic cylinders and replacing with Hydra- Pneumatic cylinders operated by simple pneumatic valves. Each dial location now includes the integral LVDT and Load Cell options demonstratively called IntelliCyl® along with the HyperView-Press® Signature Analysis Monitor. The HyperCyl® solution actively measures the stud & bearing insertion depth by establishing a series of “windows” around critical points of the operation, namely the part stack-up (part contact) and final depth. ONLY when critical stack up “window” was confirmed would high pressure then activate to finalize the part. This provided key measurement of the operation ultimately reducing in-process part non-conformance to near-zero.
Aries Engineering/HyperCyl® was able to accommodate this OEM’s needs and reduce overall operating costs by removing outdated hydraulics and free up floor space in the process. We can also help you improve the quality of your product while reducing your costs and allowing your business to maintain the competitive edge. HyperCyl offers Hydra-Pneumatic and Servo Actuator solutions, applications engineering, testing, tech-support and the best warranty in the industry! “Speed, Precision, Power”. MADE IN U.S.A.!
Find out how HyperCyl can help meet your application needs, email [email protected].
Comments Off on Improving Quality and Reducing Costs In Seal Manufacturing
A major U.S manufacturer of steel-cased, multi-element seals contacted Aries Engineering/HyperCyl® for help in reducing excessive warranty costs of their finished product. The OEM was experiencing in excess of $10 million per year in warranty claims due to their current hydraulic presses’ inability to monitor the number of elements within a given assembly. They needed a press and monitoring system that could accurately measure the number and thickness of seal components within a sub-assembly prior to being finalized.
Aries Engineering supplied the solution with our HyperCyl IntelliCyl® cylinders with integral LVDT and Load Cell options, combined with the HyperView- Press®, our Signature Analysis Monitor, which provided measurement of the Part Stack-Up height prior to finalizing the seal. This ultimately reduced in-process part non-conformance to near-zero. The HyperCyl monitoring systems were able to accurately measure the inclusion or absence of a 0.002” thickness seal element by establishing a series of “windows” around critical points of the operation, namely the part stack-up. ONLY when this critical “window” set point was confirmed would high pressure then activate and finalize the process. Aries Engineering/HyperCyl® was able to accommodate this customer’s needs and reduce overall warranty claims to less than $60,000 annually, a savings well over $9 million per year!
We can also help you improve the quality of your product, while reducing your costs and allowing your business to become more competitive. We offer Hydra-Pneumatic and Servo solutions, applications engineering, testing, tech-support and the best warranty in the industry!
Find out more about how we can meet your application needs, email [email protected].
**1. An infeed conveyor provides the subassembly to the gripper location. 2. From there, the gripper will load the seal into the nest cavity. 3. The HyperCyl cylinder with IntelliCyl force/distance feedback assembles the filaments and forms the final shape. 4. From there, only when the part is validated and passes a series of inspections it is automatically able to be removed from the cell into a container. 5. Any parts that do NOT pass inspection are automatically redirected into a bad parts bin for scrap. 6. Isolating these good and bad parts is crucial for the prevention of part-non-conformance.
Comments Off on Using Cleaner Technology for a Brighter Factory
Outdated Hydraulic systems require constant maintenance and high cost pumps, Pure Pneumatic systems lack the force and controllability, Arbor Presses and Hammers exhaust my employees, Flywheels are dangerous; if these problems sound familiar you’re not alone. Why not use a clean, reliable, consistent & cost-effective product to REPLACE all of these? The Solution is HyperCyl!
In most automated assembly applications which can be insertion, piercing, forming or assembling, the key ingredients to a successful project are precision, accuracy and repeatability. Continuous Quality Control over these processes that can determine good/bad parts while in motion is the new norm. HyperCyl-EMA, HyperCyl hydra-pneumatic & HyperView-Press are just a few of the options that have made HyperCyl a one-stop solution provider for over 25 years.
*HyperCyl-EMA (electro-mechanical actuator) is a robust, servo driven actuator designed for precision assembly applications or applications not suited for standard HyperCyl products. Available in both Roller Screw and Ball Screw configurations with load ratings from 5kN to 230kN (1-25 tons), HyperCyl-EMA provides a new level of price/performance in the automotive, aerospace, DOD, appliance, medical, electronics and transportation industries covering a wide range of applications. Capable of extremely high rates of repeatability and up to 500mm/sec ram speeds, HyperCyl-EMA provides the performance and flexibility required in both current and future manufacturing environments and, it’s built in the USA.
*HyperCyl (hydra-pneumatic cylinder) is a low cost air/oil solution that can replace outdated technologies with a more precise, controllable stroke. Not your grandfathers air/oil unit, we have re-packaged the 3-piece air/oil design into a single self-contained unit ready for use upon shipment. Available from 5kN to 1,780kN (1-200 Tons) using ONLY shop air, HyperCyl provides a long-life cylinder that is simple to maintain, runs on 2 pneumatic valves, requires no drip pans or expensive cooling systems but also boasts a LIFETIME warranty.
*Available for both the EMA and HyperCyl is the HyperView-Press signature analysis controller. Precise force/distance monitoring coupled with trending, data logging, Cpk and data analysis capabilities will profoundly improve finished product quality and substantially reduce manufacturing costs. During the cycle, the unit gathers information from the Inputs (Analog or Encoder) and provides a wave-form curve with user-adjustable windows indicating what a Valid/Good part is. The “Window 7” embedded software provides the best of both worlds: ease of use/setup and the deployment simplicity of an off-the-shelf solution tailored to your exact press monitoring requirements.
Find out how we can help solve your application needs, email [email protected].
Comments Off on “Punching and Shearing” Tips and Tricks
Aries Engineering/HyperCyl is a diversified manufacturer of Hydra-Pneumatic Cylinders, Servo Actuators, Presses, Pierce Units and Joining Systems designed for use in a wide range of assembly
and forming applications. HyperCyl has a place in virtually every segment of industrial production. HyperCyl has a proven track record in thousands of applications as a clean, quiet, reliable, self-contained power source utilizing only compressed air to generate ample output forces from 3kN – 1,780kN.
The formula to calculate punching force is quite simple:
Force = Hole Perimeter (length of cut) x Material Thickness (aluminum, steel, stainless) x Shear Strength or Tensile Strength (depends on type of punch being used). You must make sure that you keep your units consistent between Metric and Imperial.
Metal Forming
Forces required for metal piercing can be calculated as follows:
L= Length
T= Thickness of Material
S= Shear Strength of Material
L x T x S = Force Required
(stripping force= 10% of Pierce Force)
Stripping force is the force required to typically remove or retract the punch after it has pierced the material.
Example:
3/8 ” (.375″) hole through .032″ thick CRS (cold rolled steel)
L= 1.178 (.375 x 3.141)
T= .032
S= 55,000
1.178 x .032 x 55,000= 2090 lbs.
Here are some helpful tips and tricks for punching and shearing applications:
*While the ultimate Tensile strength is used for initial calculations for flat punch designs, the formula for using full tensile strength is applied at the onset to establish a WORST-CASE scenario for sizing our cylinders. Real life tensile can vary based on mold/forming time, cooling time, work hardening (if applicable) and a host of other miscellaneous factors. We don’t see as much variation with Aluminum castings as we do with steel.
*We can provide parts-testing data and extrapolate from our testing for a 0.25”, 0.375”, and 0.500” nominal punch holes to determine the actual tensile/shear strengths and calculate real life forces, factoring in the flat punch or shear punch designs.
*Not everyone uses Shear in the punch head, MOST use a flat punch so it can be sharpened easily and reused for many years. When using SHEAR in your punch head, the Shear Strength can be used for force calculations.
*In all piercing applications, a “stripper” or positive force on the part DURING punching operation should be considered so the part can remain located in nesting during retraction of the punch from part. If absent from your design, the part will retract with the punch during retract.
*There are numerous versions of shearing punch designs which directly correlate to forces required:
-High angle, straight cut (think scissors)
-Rooftop
-Inverted Rooftop
-Inverted Rooftop
-Double Valley
-JK Shear (flat punch, using Tensile strength, NOT shear strength)
Find out more how HyperCyl can help meet your application needs, email [email protected].
Comments Off on How To: Determine the Appropriate Technology for High Force/High Speed Applications
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
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.
Comments Off on Can HyperCyl meet your application needs?
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.
Industries
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:
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.
Comments Off on Hydraulic vs. Pneumatic vs. Electric Actuators
Actuators are mechanical devices that use energy to generate motion. Manual or automatic control commands initiate change in physical systems, creating motion to perform a task. Actuators allow machines to lift, block, clamp, eject and more.
Depending on the type of energy source used to produce motion, three main types of actuators are available: hydraulic, pneumatic and electric. Below we’ll review the characteristics of these actuators as well as their applications and advantages.
Hydraulic Actuators
Known as the most commonly used energy conversion system, hydraulic actuators are an especially popular choice for systems requiring high-force automation equipment. These actuators rely on oil fluid compression.
A variety of heavy-duty applications use hydraulic actuators to produce anywhere from ½ to 4,000 tons of force. These potential applications include:
Cargo handling
Large construction equipment
Military weapons
Marine propulsion
Transportation systems
Advantages of Hydraulic Actuators
Hydraulic actuators bring the following benefits to an operation:
Good strength-to-weight ratio: Hydraulic actuators can deliver tremendous force relative to their weight.
Safety: They include various safety features, including rod locks, dump valves that quickly dissipate energy, and bypass valves that close off high-pressure oil when generating motion.
Mobility: Hydraulic actuators are also compact enough to take on mobile operations, servicing trucks and other heavy transportation equipment.
Pneumatic Actuators
Most pneumatic actuators feature compression rates of 80 to 100 psi, making them a more stable and safe option for applications requiring less force. These actuators capture atmospheric air and compress it at higher pressures to generate motion. The specific parts of a pneumatic actuator include the actuator, storage tank, system of delivery hoses, motor and compressor unit.
Advantages of Pneumatic Actuators
The benefits of pneumatic actuators include:
Speed: The fastest actuators are pneumatic. Fast cycle rates contribute to greater productivity and profit.
Cost effectiveness: Pneumatic actuators have lower upfront costs compared to other actuators. They return their initial investment quickly, especially for moderate-duty applications.
Simplicity: Pneumatic actuators are relatively simple, so they are less likely to malfunction and easier to repair if they do.
Electric Actuators
Electric actuators use a motor to convert electric energy into torque, producing motion. They use a variety of mechanical components—gears, planetary roller screws, ball screws, lead screws—to generate linear energy from rotational energy.
Small electric actuators are best for low- to medium-duty applications, such as packaging, factory robotics, automotive manufacturing and medical devices. Large electric actuators can produce up to 50,000 lbs of force.
Advantages of Electric Actuators
Electric actuators provide the following main benefits:
Speed: Electric actuators respond quickly to generate motion, with speeds of up to 20 in./sec.
Precision: Unlike hydraulic and pneumatic actuators, electric actuators are highly precise because they are not subject to inherent tolerances.
Cleanliness: Electric actuators use electricity, a clean energy source, eliminating the risk of leaks.
Electric Actuators from Aries Engineering
Aries Engineering produces the HyperCyl-EMA, one of the most reliable electromechanical actuators on the market. This servo-driven actuator works well for precision assembly applications and as substitutes for hydraulic or pneumatic actuators. Our electric actuators are capable of 0.0025 mm, ram speeds of up to 500 mm/sec, and up to 50,000 lbs of output. The HyperCyl-EMA has served customers in the aerospace, automotive, defense, medical, appliance, electronics and transportation industries.
Find the Actuator You Need at Aries Engineering
Aries Engineering Co., Inc. manufactures a line of “hydra-pneumatic” presses and cylinders for many types of assembly applications. We pioneered oil/air compression in 1994 and continue to serve clients across the manufacturing, industrial automation, defense and commercial industries.
If you would like to find out more about our HyperCyl-EMA electric actuators and other products, contact us today. To get started on your next solution, request a quote at any time.
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.
