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Hydraulic Cylinders and Cylinder Systems for Mobile Hydraulics
HYDROSAAR, part of the global HYDAC group, develops and manufactures a broad range of hydraulic cylinders and cylinder systems for mobile applications. Drawing on our knowledge base, we develop the most appropriate hydraulic cylinder solution for your application. For example, innovative position sensor technology can be installed, or the cylinder piston rods can be supplied with special surface coatings. Our cylinder engineering includes design and calculations performed with cutting-edge 3D CAD and FE tools. Each cylinder is optimised individually to fulfil the customer’s specific requirements. Hydrosaar has been engaged in mobile hydraulics for more than a decade, supplying global manufacturers of cranes, construction machinery, agricultural machines and specialpurpose vehicles.
Your Partner for Expertise. For cylinders and cylinder systems in mobile applications
Cylinder solutions for all customer requirement
Engineering expertise
At a glance
Development / design / strength calculation / testing
Telescopic systems z Single-cylinder telescopic systems
To fulfil the stringent requirements required of the final product, we employ the latest technology: z 3D design z Finite element calculation for optimised design z Structural analysis z Non-linear stability calculations z Structural durability analysis
z Securing locking system z Telescopic guide system z Controller
Boom, outrigger and special cylinders
Surface treatment processes
z Weight-optimised, space-saving design
z Electroplating z High-speed flame spraying and plasma spraying (metallic and ceramic coatings) z Induction melting of compound layers z Laser-welded and plasma-welded layers z Customised paint finishes (corrosivity categories up to C5-M)
z Integrated valve technology and sensors
Mining and excavator cylinders z For high dynamic loads
Lightweight
z Structurally durable design
z Weight-optimisation z Use of high-strength steel materials z Use of light metal and fibre-composite materials Production capabilities: z Cylinder strokes up to 12,000 mm z Piston diameters up to 600 mm z Differential cylinders z Synchronising cylinders z Plunger cylinders
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z Telescopic cylinders
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Functional safety – integrated sensors The technical requirements with regard to functional safety are based on the standards IEC 61508 and EN 13849. HYDAC provides: Controllers certified to - IEC 61508, SIL 2 (3) - EN 13849, Pl d (c) Other components for applications with increased functional safety - Sensors - Valves Support provided throughout, from risk analysis to certified machine function
EN 954-1
EN 13849-1
IEC 62061
Suspension and accumulator cylinders
IEC 61508
Machinery industry
z Cylinder-integrated accumulators
(electronics, hydraulics, pneumatics, mechanics)
z Combined cylinder/accumulator solution z Self-supporting suspension struts
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Cylinders for mobile technology. Light. Compact. System-based. Production expertise Manufacturing techniques Cutting-edge machine equipment that can be used for all kinds of machining work: - Deep-hole boring - Turning (CNC, NC and conventional) - Honing - Milling - Grinding - Welding
CNC lathe (12 m turning length)
Automated submerged-arc welding system
Assembly and test bench z Cleaning and cylinder-assembly equipment z PLC-controlled hydraulic test benches for test pressures up to 1200 bar z Function and fatigue test benches
Paint application Cutting-edge paint technology for protection against wear and corrosion. z Sandblasting z Cleaning z Painting z Drying
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Top quality is guaranteed by constantly monitoring all processes (from design to assembly), inspecting individual parts as well as finished products, monitoring of measuring equipment and contamination monitoring of the hydraulic oils used. Consistent quality is the result of very close collaborative relationships with customers and suppliers.
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Quality assurance
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Telescopic systems for mobile cranes Telescopic systems In modern mobile cranes, the main boom is extended and retracted by a single-cylinder telescopic system. The systems are made up of the following main components: z Double-acting hydraulic cylinder in lightweight design z Guide frame z Securing locking unit (SLU) z Hydraulic accumulator unit including valve control
Control and display
z Internal oil feed
z Telescopic guide system adapted to suit specific cranes
z Telescopic boom and position detection z Position sensor system (optional)
z Reliable, flexible HY-TTC 90 controller, certified to ISO 13849
In addition to customised systems, a system with the in-house developed SLU is available.
z Universal mobile display with integrated HY-eVision controller
Operating pressures: up to 350 bar
z Customised control and visualisation software based on standard modules
Stroke: up to 12,000 mm
Advantages and features:
Advantages and features:
z Complete hydraulic/mechanical/electric system from a single source
z Complete telescopic system package including control
z Flexible cylinder sizing
z Customised visualisation
z Specific interface programming
z Cylinder and SLU produced to customer specifications or our own design
z On-site commissioning support
Securing locking unit – base mounted
Universal mobile display with integrated HYeVision controller
Flexible HY-TTC 90 mobile controller
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Functional Safety PL d SIL 2
Telematic system
Controllers and visualisation
Functional Safety PL d SIL 2
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Flexible HY-TTC 500 mobile controller
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Telescopic systems for mobile cranes
z Minimal cylinder weight
Boom, outrigger and special cylinders Boom cylinder
Cylinders for vehicle outriggers
The boom cylinder alters the angle of main booms and jib booms on cranes and construction machinery. As the weight is generally restricted by permissible axle loads, boom cylinders are designed to be lightweight. High-strength materials are used and modern calculation methods are applied to optimise the design of the cylinder components. The piston rods are normally manufactured from hollow tubes.
Mobile cranes and special-purpose vehicles that support and move loads have outriggers installed on the vehicle frame. Several cylinders are normally used for extension, pivoting and support. Like the boom cylinder, the cylinders are lightweight and meet strict requirements regarding leak-tightness. Hydrosaar provides solutions with integrated sensors, particularly position and pressure sensors, to satisfy the most stringent requirements for comfort and safety (in line with EN 13849).
Counterbalance valves or load-holding valves can be integrated into the cylinder or into blocks installed directly on the cylinder. Hydrosaar manufactures boom cylinders with piston diameters of up to 600 mm and strokes of up to 9000 mm.
Outrigger cylinder for mobile crane with special mounting
Lightweight boom cylinder for telescopic crane
Benefits and special features:
Benefits and special features:
z Lightweight design
z Outrigger cylinder for static pressures of up to 600 bar with integrated valve technology
z High-strength materials used z Special seals prevent any leakage z Integration of valve technology z Structurally durable design
z Extension cylinder, single- and multi-stage z Complete cylinder systems for specialpurpose vehicles and crane outriggers z Corrosion-resistant piston-rod coatings
Two-stage horizontal cylinder for outrigger
Special cylinders for cranes
Steering and suspension cylinders
Hydraulic cylinders are used for various special purposes in cranes, for example to lift or move counterweights, as mast fall-back prevention cylinders or bolting cylinders, to extend or raise masts or also to tension crawler tracks. The cylinders are developed and produced in line with customer requirements, as appropriate for the particular task. Hydraulic valves, sensors and also integral tanks are frequently integrated directly into the cylinder.
In the chassis of mobile cranes and construction machinery, hydraulic cylinders are used in steering and suspension functions. Hydrosaar suspension cylinders and steering cylinders boast low-friction guide & seal systems and coatings tailored to suit the operating conditions. Integrated position sensor systems from the HYDAC HLT series and HYDAC pressure sensors are available for the cylinders.
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In addition to offering cylinders as components, HYDAC also manufactures complete suspension and steering systems.
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Steering cylinder with integrated position sensors
Benefits and special features:
Benefits and special features:
z Weight-optimised design
z Integration of accumulator
z High-strength materials used
z Low-friction design
z Integrated valve technology
z Integrated end position damping
z Integrated anti-rotation piston rod
z Integrated position sensor technology Counterweight cylinder with integrated valve technology
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Mast fall-back prevention cylinder with integrated valves, integral tanks and anti-rotation
The suspension cylinders can be supplied with accumulators integrated into the cylinder as well as external accumulators.
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Boom, outrigger and special cylinders for cranes
Seal and guide systems ensure the cylinder moves evenly with little friction and the load is held leak-free over the entire operating-pressure range.
Construction machinery and mining Excavator cylinders
Road construction machinery
Cylinders used in excavators, particularly large excavators and mining excavators, have to demonstrate a high degree of robustness and availability.
Hydrosaar supplies cylinders for road construction machinery which meets the strictest standards for durability and functional efficiency. The cylinders are tailored to suit the construction machine to make the best use of the available space. If desired, the cylinders can be fitted with integrated valves, position sensors and pressure sensors, and also internal oil feed.
Hydrosaar supplies boom, stick, bucket, jaw and track-tensioning cylinders. The cylinders are designed for structural stability even at high cycle rates. A long service life is guaranteed, thanks to special piston rod coatings, combined with seal and guide systems that are designed specially for the particular application.
Jaw cylinder for mining excavator
Benefits and special features:
Benefits and special features:
z Robust design for dynamic application
z Vibration-resistant design
z Structurally durable design for high cycle rates
z Special sealing systems
z Integrated position sensor technology
z Integration of position sensor technology
Lift cylinder with integrated oil feed
Boom cylinder with integrated position sensor system
Rotary joints
Mobile mining machines
For excavators, cranes and other construction machinery, Hydrosaar offers customised rotary joints.
Hydraulic cylinders for mobile machines used in surface mining and tunnelling are put under great strain as a result of contamination and temperature. To withstand such loads, the Hydrosaar cylinders designed for these applications are extremely robust. Appropriate materials are used along with special piston-rod coatings, wipers and seal and guide systems to guarantee a long service life.
The rotary joints can be configured in terms of the number of ports, port size and port design. To ensure long service life, the rotation pistons are supplied with a special coating. If desired, the hydraulic ports can be supplemented with compressed-air ports and an electrical feed.
Benefits and special features: z Robust design
Benefits and special features:
z Special coatings
z Up to 16 ports
z Special sealing systems
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z Integration of position sensor technology
z Piston coating for maximum service life
z Integration of valve technology
z Integration of compressed-air and electrical feed
Hydraulic rotary joint for large excavator, 16-port
Expansion cylinder for tunnel boring machine
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z Up to 420 bar
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Construction machinery and mining
z Integration of valve technology
Suspension and accumulator cylinders Active heave compensation
Real-world examples
Energy consumption is of increasing importance, particularly in the machinery used in transshipment operations. Hydraulic systems for energy recovery and active heave compensation play a major role in reducing consumption. HYDAC supplies machine builders with system solutions which include cylinders, accumulators and valve equipment as primary components. In addition to cylinder/accumulator combinations, HYDAC provides cylinder-integrated solutions.
Suspension-damper cylinders Cylinders provide suspension and damping during vehicle travel in many mobile machines, from large mining vehicles to agricultural machinery. Hydrosaar supplies hydraulic cylinders with integrated gas accumulators, developed specifically to take account of the customer’s requirements in respect of suspension characteristics, forces and installation space.
Working load
Base load
Force
Compensation force
Residual load Stroke
Benefits and special features:
Active heave compensation: Material handler
Benefits and special features:
z Open and closed hydraulic systems
z Combined cylinder/accumulator system for active heave compensation
z Adjustable damping characteristics z Designed according to Pressure Equipment Directive
z Reduced drive power and operating costs
z Self-supporting design possible
z Designed for specific application
z Piston-rod coating tailored to suit operating conditions
z Low-temperature design (to -40 °C)
z Low-temperature design (to -40 °C)
Action/strategies: z Energy recovery z Downsizing z Boost operation Benefits: z Reduced fuel consumption z Productivity increase z Noise control
Quasi-statistical suspension characteristics, ∆z = ±35 mm, f = 0.5 Hz
275 250 225 200
Force in kN
175 150 125 100 75 50 25 0
0
10
20
30
40
50
60
70
80
Distance in mm
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Suspension cylinder with integrated accumulator
Cylinder for active heave compensation system
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Suspension characteristics, suspension damper cylinder
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Suspension and accumulator cylinders
z Cylinders with integrated or external hydraulic accumulators
HYDAC Headquarters HYDAC Companies HYDAC Sales and Service Partners
Accumulator Technology 30.000 Cooling Systems 5.700
Contact HYDAC INTERNATIONAL GMBH
Hirschbachstr. 7 66280 Sulzbach/Saar Germany Tel.: +49 6897 509-9700 Fax: +49 6897 509-9791 Email:
[email protected] Internet: www.hydac.com
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Electronics 180.000
Accessories 61.000
Compact Hydraulics 53.000
Fluid Service 79.000
Process Technology 77.000
Filter Technology 70.000
Global Presence. Local Expertise. www.hydac.com
