Dual Cylinder Actuation Evolution

Traditional clamp and press mode actuation applications present the challenge of having a rapid stroke at a low force, while requiring a steep ramp-up to a high force for a short period. The inherent nature of achieving these demanding performance parameters typically means expensive oversizing of the hydraulic infrastructure to provide the high speed and high force necessary.

Within this large machine footprint, delivering the requisite position and force control goals present complex motion and expense variables. In addition to having too many overall pieces in the equation, other factors include: oversized and continuously running pumps, large hoses that often leak and require maintenance, and the energy consuming frequency of stopping/starting with valves repeatedly turning on/off, while transitioning from high speed (low force) to lower speed (high force).

In an effort to overcome and revolutionize the problem of having to oversize actuation components for applications that have a rapid stroke at low force with a load stroke at high force–cutting-edge motion control/actuation specialists Kyntronics (Cleveland, OH) have developed their patent-pending HSHF (High Speed/High Force) All-In-One Actuator. Combining key technologies from their servo-based SMART Hydraulic Actuator (SHA), coupled with a high-speed actuator and a high-force pair of actuators–the HSHF delivers an industry changing, cost effective solution in a scaleable, modular, ‘power-on-demand’ machine platform. The design is self-contained with no hoses that eliminates the expensive leaky infrastructure.

Ultimately, the unique dual cylinder system configuation delivers a myriad of benefits, resulting in lower operating costs and better performance across a wide range of OEM applications.

TRADITIONAL CLAMP & PRESS MODE ISSUES / CLIMATE:
Made in the USA, this new actuation technology is a leap in modularity, and takes advantage of hydraulics to overcome inherent issues with existing clamp and press mode technologies including:

Clamp Mode: In this mode, rapid cycling times are needed while holding a lot of force (170,000 Lbf / 756kN) going back and forth. This mode is predominant in injection and blow molding applications which require rapid back/forth position and hold, which puts a lot of pressure on the actuator.

Traditional systems include hydraulics which feature check valves that lock in position. This requires a large footprint with a large pump and huge hoses, is noisy, and expensive. Electromechanical is also an option but this requires very large and expensive components including; motors, gearboxes, and roller screws/ball screws. Furthermore, because it is always applying loads at the same mechanical position, this consistent metal-to-metal contact results in reduced life.

Press Application: Typically, this mode is used for 20-80 ton presses which need to come down quickly, and do work within a small distance (¼”-½”[6-13mm]) for small periods of time. This application is currently dominated by hydraulic systems with huge power units, and excessive pumps/hoses.

Ultimately, Kyntronics’ uniquely configured HSHF system delivers accurate force control for both clamping and press applications optimal performance. This next generation of actuation provides reliable, rapid movement with high force clamping, and reliable movement with a high force press (small distance)–at a low cost, with no hoses, in a small envelope.

Key Kyntronics HSHF Actuator performance specs include:

• Servo Drive with Integral Motion Control.
• High Load: >85 tons <2 sec.
• Load Stroke / High Force Actuation Cylinders Up to 170,000 Lbf (756kN) of force.
• High Speed / Rapid Stroke Actuation Cylinder Up to 45.6 in/sec (115.9 cm/sec) with up
• to 4,081 Lbs. (18.2 kN) of force.

KYNTRONICS HSHF ACTUATOR INNOVATION / DESIGN BENEFITS:
A true, ‘all-in-one’ solution (controller and programming included), the HSHF’s multi-cylinder, drop-in design features a variable displacement pump, servo motor, servo drive/motion controller, and closed-loop position and force control, with precision position and pressure sensors.

This revolutionary simple design eliminates oversizing methods, and solves a lot of issues associated with current options (no hoses, quieter operation, more connectivity, etc.) in a very cost effective, reliable small package– representing upwards of 50% savings in equipment and operating costs.

HSHF single “high-load” cylinderThe reduced space and machine footprint is significant, as it eliminates the hydraulic infrastructure and all oversized elements–providing significant cost savings. Because it only uses power-on-demand, energy savings are built-in. Since there is no huge cylinder or large pump waiting for the cycle to start, the HSHF uses minimal energy for the long stroke and proportional energy for the load stroke.

Ease-of-integration with machine control systems and versatile control is also an inherent benefit, as the HSHF Actuator is compatible with Fieldbus, I/O (selectable indexes), and Analog (0-10vdc or 4-20ma).

KYNTRONICS HSHF ACTUATOR PATENT-PENDING / DUAL CYLINDER DESIGN DIFFERENCE:
The HSHF Actuator’s patent-pending concept incorporates a new approach to the established hydraulic cylinder design by mechanically connecting a high- speed cylinder to a larger high-force innovatively designed dual cylinder (patent pending).

The dual cylinder combines a larger (high speed zone) cylinder (e.g. a 6 in) and a slightly smaller (high force zone) cylinder (e.g. a 5 in) together with a unique piston which is designed to seal in the smaller cylinder and move freely through the larger cylinder. The high-speed cylinder pulls (e.g. a 1in) the dual cylinder’s unique piston through the longer stroke (i.e. oil flows freely around the piston) into the smaller cylinder (high force zone) and seals the piston allowing for either the press or clamp mode. The cylinders can be adjusted to any desired length.

With SMART actuation, the system knows the exact position where the unique piston enters the smaller high force cylinder zone and creates a seal. As the smaller high-speed cylinder approaches the high force zone, the system slows down and seamlessly combines the fluid flow to both the high-speed cylinder (e.g. 1 in) and the high-force cylinder (e.g. 5 in) without stopping the motion. The system continues to press forward to the desired location based on force or position. After the operation is completed, the high-speed cylinder retracts pulling the unique piston back to the retract position. The high-speed cylinder provides the speed to reduce the overall cycle times with minimal flow, force and heat reducing overall energy consumption.

Ultimately, the HSHF Actuator design delivers rapid controlled clamp mode and seamless press mode in transitioning from HS-to-HF cylinders–with accurate force and position control.

During a press mode, maximum power is required for a short period of the cycle (slower speed with high force)–minimizing the motor and drive size along with the overall heat.

During a clamp mode, minimum power is required to rapidly move the cylinder (extend/retract). During the clamping, zero power is required as the check valves in the HF cylinder lock the actuator in position and the HS cylinder is placed in float mode to prevent cylinder damage.

HSHF APPLICATIONS / CONCLUSION:
A leap in hydraulic technology and modularity, Kyntronics’ HSHF Actuator will benefit a myriad of unique applications that require a rapid stroke with a small press load, combined with a short stroke with high load in a small period of time. The all-in-one operation delivers an optimal servo-controlled, closed loop-controlled force, as well as a closed loop-controlled position solution.

Vertical market industries such as Automotive, Aerospace, Packaging, and Plastics, with unique applications including Injection Molding, Blow Molding, Toggle/Platen Clamping, Metal Forming, Injection Carriage Actuation, Trim Press Actuation, Thermoforming Platen Actuation, along with many others will benefit from HSHF Actuators lower costs and higher precision.

According to Kyntronics’ President, Wayne Foley, “The HSHF Actuator is a production enhancing product via cycle time reduction at a lower cost vs. current alternative hydraulic and electromechanical options. Accurate position, force, and speed control move quickly under the low load, then the balance of the cycle (5-10%) retracts/repeats quickly like nothing else on the market. Ultimately, as we aggressively launch in 2019, OEMs will benefit the most from this game-changing, dual cylinder actuation evolution.”

Noting the product’s ease-of-application as a competitive and advanced alternative for the clamp/press mode marketplace, Carl Richter, Kyntronics VP/General Manager, said, “We strive to provide our customers and channel partners with unique solutions like the HSHF that are ahead of the curve. Our nimble, responsive team of in-house engineers thrive on ‘solving the unsolvable’ actuation application problem. The HSHF is revolutionary as its modularity, power-on-demand, and multi-cylinder capabilities save time, energy, and money for OEMs across the board.”

Kyntronics is leading the way for advanced actuation for wide-ranging applications and markets including: Special machines, Automotive, Aerospace, Medical Equipment, Metal bending/forming, Defense, Material Handling, Testing Stands, Steel Mills, Lift Tables, and many others. All Kyntronics products are made in the USA, competitively priced, and comprehensively backed by a customer service support system that is unparalleled in the industry.

About Kyntronics, Inc.

Since 2010, Kyntronics has emerged as a leader in ‘new technology’ motion control and actuation product development. The ISO 9001, AS9100D certified company is rooted in providing leading-edge, customer-centric, and differentiating actuation solutions for a myriad of today’s small-to-large OEMs. Made in the USA, Kyntronics’ actuation products drive efficiencies for applications across the industrial spectrum– from drop-in replacement actuators for existing applications, to custom engineered actuators and complete motion control systems. With vast experience in industrial, aerospace, and medical industries, our in-house team of mechanical, hydraulic, electronic, and software engineers combine to provide hundreds of years of engineering acumen.