Roller Screw Actuators Archives - HyperCyl
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Tag Archive: Roller Screw Actuators

  1. HyperCyl Case Study: HyperCyl-EMA Actuator Reduces Customer Costs and Down-Time

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    A food grade paper tray manufacturer contacted Aries Engineering/HyperCyl® to reduce electricity expenses when replacing (20) 30-Ton hydraulic presses. Their current hydraulic cylinders were costing them approximately $180,000 in electricity yearly, not including maintenance costs and the cost of hydraulic fluid disposal. The manufacturer chose the HyperCyl-EMA®, our Electro-Mechanical Actuator, which provided a cost savings to our customer in excess of $100,000 annually, when compared to the hydraulic units previously used. Extreme Accuracy, Quality, and cost savings allows HyperCyl-EMA® to compete with any electric or hydraulic cylinder on the market!

    The ability to apply force the entire length of the stroke makes HyperCyl-EMA® widely suitable for use in applications such as Pressing, Stamping, Assembly line or Robot installations and other various high force/highly accurate projects. HyperCyl® currently provides high force solutions to many diverse industries such as Medical, DOD, Munitions manufacturing, Tier 1 automotive companies and Aerospace manufacturing. Standard equipment includes the Emerson UniMotor, Internally mounted temperature- compensated Load Cell, Standard Internal Non-Rotate and End of stroke Proximity sensors. EMA is available in standard stroke lengths of 8.00” and 14.00”. Please contact the factory for additional stroke availability. We also offer the HyperView Press signature analysis controller, with 10” TFT touch-screen for Live-Time Quality Control over your application while in-process.

    These exceptionally accurate actuators (.0001”) have a high rate of repeatability and create a cost- effective alternative to hydraulic units because of their no fuss installation, limited maintenance schedule and user-controlled adjustability. Complete tooling-ready TurnKey presses, as well as standalone actuators are available upon request.

    Find out how HyperCyl can meet your application needs, email [email protected].

  2. Using Cleaner Technology for a Brighter Factory

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    Outdated Hydraulic systems require constant maintenance and high cost pumps, Pure Pneumatic systems lack the force and controllability, Arbor Presses and Hammers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].

  3. 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.

  4. 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.

    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:

    • 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.

  5. Ball Screw Actuators vs. Roller Screw Actuators

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    Actuators are mechanical devices that convert energy into motion. These components are incorporated into a wide variety of products, from industrial equipment to household electronics. The energy source of an actuator can be electric, hydraulic, or pneumatic power.

    High-quality, heavy-duty actuators are critical for industrial operations, where they are responsible for facilitating linear and rotary motion to convey materials and operate equipment. For heavy-duty operations, ball screw actuators and roller screw actuators are ideal. We will explain the characteristics, benefits, and differences between ball screw and roller screw actuators so you can choose the one that best suits your needs.

    Ball Screw Actuators

    Ball screw actuators convert rotary motion to linear motion. They feature a nut mounted on a grooved screw shaft. Inside the nut, recirculating balls roll within the groves of the screw shaft. As the screw turns, the nut moves up and down the shaft along the grooves, creating linear motion that can be finely controlled by turning the screw. Ball screw actuators provide precise control for medium-duty to heavy load-bearing applications and can accommodate high-speed processes.

    Ball Screw Applications

    Ball screw actuators provide smooth, energy-efficient motion with exceptional accuracy and precision control. They offer continuous high-speed, high-force movement for long periods of time. These benefits make ball screws ideal for:

    • Sawmills
    • Wind turbines
    • Solar panels
    • Vehicle power steering
    • Assembly equipment

    Roller Screw Actuators

    Roller screws have a similar construction to ball screws, but instead of recirculating balls, they contain rollers that are threaded to match the threads on the main screw shaft. Since the rollers do not touch each other, they do not interfere with each other’s motion and can operate significantly faster than ball screws. The individual rollers have greater surface area contact with the main shaft than recirculating balls, so they have higher axial load characteristics, higher dynamic load capabilities and thus longer life than comparable ball screws. They also generate more heat and require more lubrication at tighter intervals.

    Roller Screw Applications

    Roller screws can withstand high force and repetitive motions for long periods of time. They can be controlled with a high degree of precision, and their extensive surface area provides additional stress dispersion in high-force applications, such as:

    • Automotive and aerospace manufacturing
    • Metal casting and molding
    • Paint spraying
    • Pressing, inserting, and riveting
    • Precision CNC machining
    • Automated, high-speed manufacturing equipment

    Which Actuator Is Right for You?

    Ball and roller screws each offer unique advantages for different applications. To determine which actuator is ideal for your needs, consider the following:

    • Operational Life: In general, roller screws have a longer service life and offer good ROI when operated for extended periods of time. For projects lasting less than three years, ball screws are highly effective and make an excellent investment. Depending on the budget and length of your project, ball screws may be ideal for short-term, low-budget projects, while roller screws would be better for long-term applications.
    • Expected Force: Longevity is greatly affected by the amount of force exerted. Roller screws are better than ball screws for heavy loads over eight tons. For applications with lower load capacity, balls screws represent an excellent low-cost option.
    • Maintenance Frequency: Due to the amount of friction and heat they generate, roller screws often require more lubricant and maintenance than ball screws, especially in high-speed operations. Both types of actuators operate best with sufficient lubrication and regular preventative maintenance.
    • Contact Area: Due to the lack of contact between rollers and the bearing, roller screws transmit more force more quickly. Ball screws must make contact between balls and the bearing, so this can interfere with ball motion, reducing efficiency and increasing wear on the actuator elements.
    • Cost: Ball screw actuators are significantly less expensive to obtain, maintain, and repair. Components are readily available open-market, and their simple design makes them easy to fix. Roller screws, on the other hand, are more complex and contain more specialized components, which makes parts harder to source and more expensive to repair or replace.

    Request a Quote on Quality Actuators from HyperCyl

    HyperCyl is a leading developer and manufacturer of cutting-edge assembly and forming technology. We offer a selection of ball screw, roller screw, and other actuator designs to meet the needs of demanding applications in the commercial, manufacturing, defense, and automation industries. To learn more about our innovative motion solutions, contact us today or request a quote!