Hydraulic Cylinders and Cylinder Systems for Mobile Hydraulics HS-E 10.102.0/02.15 Your Partner for Expertise. Cylinder solutions for all For cylinders and cylinder systems customer requirement in mobile applications At a glance HYDROSAAR, part of the global Engineering expertise HYDAC group, develops and manufactures a broad range of hydraulic cylinders and cylinder systems for mobile applications. Development / design / strength calculation / testing Telescopic systems Drawing on our knowledge base, z Single-cylinder telescopic systems we develop the most appropriate To fulfil the stringent requirements hydraulic cylinder solution for required of the final product, we z Securing locking system your application. For example, employ the latest technology: z Telescopic guide system z 3D design innovative position sensor z Controller technology can be installed, or z Finite element calculation for the cylinder piston rods can be optimised design supplied with special surface z Structural analysis coatings. Our cylinder engineering z Non-linear stability calculations includes design and calculations z Structural durability analysis performed with cutting-edge 3D CAD and FE tools. Boom, outrigger and special cylinders Each cylinder is optimised individually to fulfil the customer’s Surface treatment processes z Weight-optimised, space-saving specific requirements. z Electroplating design z High-speed flame spraying and plasma z Integrated valve technology and Hydrosaar has been engaged sensors in mobile hydraulics for more spraying (metallic and ceramic coatings) than a decade, supplying z Induction melting of compound layers global manufacturers of cranes, z Laser-welded and plasma-welded layers construction machinery, z Customised paint finishes (corrosivity agricultural machines and special- categories up to C5-M) purpose vehicles. 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 Functional safety – integrated sensors z Synchronising cylinders Suspension and The technical requirements with regard to accumulator z Plunger cylinders functional safety are based on the EN 954-1 EN 13849-1 IEC 62061 IEC 61508 z Telescopic cylinders standards IEC 61508 and EN 13849. cylinders Machinery industry HYDAC provides: (electronics, hydraulics, pneumatics, mechanics) z Cylinder-integrated accumulators Controllers certified to - IEC 61508, SIL 2 (3) - EN 13849, Pl d (c) z Combined cylinder/accumulator Other components for applications with increased solution functional safety z Self-supporting suspension struts - Sensors - Valves Support provided throughout, from risk analysis HS-E 10.102.0/02.15 to certified machine function 2 3 5 Your Partner for Expertise. Cylinders For cylinders and cylinder systems for mobile technology. in mobile applications 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 Quality assurance 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. HS-E 10.102.0/02.15 HS-E 10.102.0/02.15 3 4 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 Reliable, flexible HY-TTC 90 controller, certified to z Position sensor system (optional) 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 z Complete telescopic system package including control system from a single source z Specific interface programming z Flexible cylinder sizing z Customised visualisation z Cylinder and SLU produced to customer z On-site commissioning support specifications or our own design z Minimal cylinder weight Securing locking unit – base mounted Universal mobile display with integrated HY- eVision controller Flexible HY-TTC 90 mobile controller Flexible HY-TTC 500 mobile controller Functional Safety Functional Safety PL d PL d SIL 2 SIL 2 Telematic system HS-E 10.102.0/02.15 Controllers and visualisation HS-E 10.102.0/02.15 6 7 systems for mobile cranes Telescopic Boom, outrigger and special cylinders Boom cylinder Cylinders for vehicle outriggers The boom cylinder alters the angle of main Mobile cranes and special-purpose vehicles booms and jib booms on cranes and construction that support and move loads have outriggers machinery. As the weight is generally restricted installed on the vehicle frame. Several cylinders by permissible axle loads, boom cylinders are normally used for extension, pivoting and are designed to be lightweight. High-strength support. Like the boom cylinder, the cylinders are materials are used and modern calculation lightweight and meet strict requirements regarding methods are applied to optimise the design of leak-tightness. Hydrosaar provides solutions the cylinder components. The piston rods are with integrated sensors, particularly position and normally manufactured from hollow tubes. pressure sensors, to satisfy the most stringent Seal and guide systems ensure the cylinder requirements for comfort and safety (in line with moves evenly with little friction and the load is EN 13849). held leak-free over the entire operating-pressure range. Counterbalance valves or load-holding valves can be integrated into the cylinder or into blocks installed directly on the cylinder. Lightweight boom cylinder for telescopic crane Outrigger cylinder for mobile crane with special mounting Hydrosaar manufactures boom cylinders with piston diameters of up to 600 mm and strokes of up to 9000 mm. Benefits and special features: Benefits and special features: z Lightweight design z Outrigger cylinder for static pressures of up z High-strength materials used to 600 bar with integrated valve technology z Special seals prevent any leakage z Extension cylinder, single- and multi-stage z Integration of valve technology z Complete cylinder systems for special- purpose vehicles and crane outriggers z Structurally durable design 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 In the chassis of mobile cranes and construction purposes in cranes, for example to lift or move machinery, hydraulic cylinders are used in counterweights, as mast fall-back prevention steering and suspension functions. cylinders or bolting cylinders, to extend or raise Hydrosaar suspension cylinders and steering masts or also to tension crawler tracks. The cylinders boast low-friction guide & seal systems cylinders are developed and produced in line with and coatings tailored to suit the operating customer requirements, as appropriate for the conditions. Integrated position sensor systems particular task. Hydraulic valves, sensors and also from the HYDAC HLT series and HYDAC integral tanks are frequently integrated directly pressure sensors are available for the cylinders. into the cylinder. The suspension cylinders can be supplied with Mast fall-back prevention cylinder with integrated valves, integral tanks and accumulators integrated into the cylinder as well anti-rotation as external accumulators. In addition to offering cylinders as components, Steering cylinder with integrated position sensors HYDAC also manufactures complete suspension and steering systems. 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 z Integrated position sensor technology Integrated anti-rotation piston rod HS-E 10.102.0/02.15 Counterweight cylinder with integrated valve technology HS-E 10.102.0/02.15 8 9 Boom, outrigger and special cylinders for cranes Construction machinery and mining Excavator cylinders Road construction machinery Cylinders used