electrohydraulic

cylinders & servocylinders

www.atos.com

Cylinders division

Big-bores assembling and testing

Cylinders and servocylinders 

1 Assembling and testing

according to ISO standard 5.000 m2 under roof  Production/year: over 30.000 Personnel, total: 45  Turnover: 10 Million 

Manufacturing plant 2

Manufacturing Facilities
All Atos cylinders and servocylinders are manufactured in the Modena facility Assembling and testing department 3500 m2 Assembling benches equipped with pneumatic screw drivers for large series production with reduced assembling time. Automatic testing benches for complete electric and hydraulic tests according to ISO 10100

Assembling department

Workshop unit - 1500 m2 Rods, bodies and tie rods are machined internally by means of automatic turning machines to satisfy the wide range of available cylinders sizes. Multi-turret simultaneous machining, CAM system management and automated workpiece loading and unloading allow to reduce scraps and machining times
3 Workshop unit 3

Range of standard cylinders

ISO 6020-2

CK square heads with tie-rods

Nominal pressure 16MPa (160 bar) max 25MPa (250 bar) Bore sizes from 25 to 200 mm Up to 3 rod diameters per bore Strokes up to 5000 mm 16 standard mounting versions 6 types of seals options Rod guide with bushing in bronze

5 CK cylinders and servocylinders

ISO 6020-2/3

CH square heads with counterflanges

Nominal pressure 16MPa (160 bar) max 25MPa (250 bar) Bore sizes from 63 to 400 mm Up to 3 rod diameters per bore Strokes up to 5000 mm 9 standard mounting versions 6 types of seals options Rod guide with bushing in bronze

CK & CH cylinders

CN Round heads with counterflanges

Nominal pressure 16MPa (160 bar) max 25MPa (250 bar) Bore sizes from 40 to 200 mm Up to 2 rod diameters per bore Strokes up to 5000 mm 9 standard mounting versions 3 types of seals options Oil ports GAS or SAE3000 threaded
7 CN & CC cylinders

ISO 6020-1

CC Round heads with counterflanges

Nominal pressure 25MPa (250 bar) max 32MPa (320 bar) Bore sizes from 50 to 320 mm Up to 2 rod diameters per bore Strokes up to 5000 mm 6 standard mounting versions 3 types of seals options Oil ports GAS or SAE6000 threaded

ISO 6022

CC cylinders

Materials
Piston Made of high resistance carbon steel and it is preloaded to avoid the unscrew and to improve the thread fatigue life Rod Hardened and tempered alloy steel with rolled threads to improve the rod strength

Heads and trunnions Realized in cast iron or steel. The wide storage of these components ensures quick deliveries

Chrome-plating Chrome thickness >20 m grants a corrosion resistance over 200h in NSS; the surface roughness Ra<0,2 m and Rmr >50% ensure extended life of sealing system

Tie-rods/screws Realized in normalized automatic steel with rolled threads to improve strenght
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Body The seamless tube is cold drawn or hot rolled according to the cylinder size. Selected materials grants high safety factors for pressures up to 400 bar

Rod bearing Rod guide is realized by a bronze bearing or guide rings for high lateral loads and low friction guide

Sealings
The wide range of available sealing systems allows the best choice for any application, according to working speed, fluid temperature and type. Polyurethane material ensures the perfect hydraulic seals, PTFE bronze filled performs high speed and very low friction. See the table below for further information.

friction pressure [bar]

1,5 1,0 0,5

seals 1

seals 8 seals 2, 4, 6, 7

50

150

250

operating pressure [bar] 9 Sealing system type 4 

Sealing system type

Material
NBR + POLYURETHANE FKM + PTFE NBR + PTFE NBR + PTFE PTFE + NBR + POLYURETHANE

Features
high static and dynamic sealing very low friction and high temperatures very low friction and high speeds very low friction single acting - pushing/pulling low friction

Max speed [m/s] 0,5 4 4 1 0,5

Fluid temperature range -20C to 85C -20C to 120C -20C to 85C -20C to 85C -20C to 85C

1 2 4 6-7 8 10 Sealing system type1 

Hydraulic cushionings
Hydraulic cushionings at stroke end are recommended for speed higher than 0,05 m/s and if there is no external softening system. Atos cushioning profiles are designed to perform an effective reduction of rod speed before hitting the mechanical stroke end and to dissipate high energies, limiting the pressure peak. The adjustable cushionings allow to optimize the cushioning performance according to the rod speed and to the actuated mass.

Speed during the cushioning

stroke end pressure

Pressure inside cushioning chamber

P max stroke end

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Rear cushioning

speed

light strong

real ideal stroke

stroke

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Regulation valve

Proximity sensors features Inductive

- Normally open contact -A  mplified signal to direct drive a relay -R  od position detection with 3 mm of adjustment

Reed
- High switching power - Suitable to directly pilot a power load - 2 wires circuit for easy connection - Max current: 500 mA

Hall effect

- Electronic sensor - Infinite electric life (no wear parts) - High sensitivity and switching reliability - Not suitable to directly pilot a power load

Proximity sensors
Fixed proximity sensors Proximity sensors can be optionally introduced on standard cylinders to detect the rod position near the mechanical stroke end. Their function is based on the variation of the magnetic field generated by the sensor itself when a magnetic element enters its influence area

CKS cylinders with adjustable proximity sensors CKS cylinders are supplied with adjustable proximity sensors to monitor the position of the rod along the cylinder stroke. Reed or Hall effect sensors can be easily assembled on one of the four tie rods by means of proper clamps which allow to position them along the cylinder body

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Fixed proximity sensors

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Adjustable proximity sensors

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Sectioned view of CKS cylinder 9

Servocylinders range
Atos servocylinders are compact motion control units and allow to achieve higher performance, top reliability and long working life. They are supplied with a wide range of position transducers with different technologies to satisfy all market requirements. Servocylinders can be supplied with on-board proportional valves

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High performance servoactuator

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CKF servocylinder

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CKM servocylinder

19 P  arison servoactuator

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CKP servocylinder

21 C  KN servocylinder with remote electronics

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Position transducers range

Code CKF CKM CKN CKP CKV

Transducer type Electronic conditioning Linearity error Repeatability

Magnetosonic, analog Integral < 0,02% F.S. < 0,001% F.S.

Magnetosonic, programmable Integral < 0,01% F.S. < 0,001% F.S.

Magnetostrictive Integral < 0,02% F.S. < 0,005% F.S.

Potentiometric None 0,1% F.S. 0,05% F.S.

Inductive Separate 0,2% F.S. 0,05% F.S.

Max speed Strokes

1 m/s 100 to 2500 Voltage: 0 10 V

2 m/s 100 to 3000 Analog: 010 V, 420 mA Digital SSI, CANopen, PROFIBUS DP Steel plants, plastic and rubber -20C to + 75C

1 m/s 100 to 4000 Voltage: 0 10 V

0,5 m/s 100 to 900

1 m/s 100 to 1000 Voltage: 0 10 V

Interface Current: 4 20 mA Typical applications Temperature limit Sawing or bending machines -20C to + 75C

Voltage 0 10 V Current: 4 20 mA Foundry and energy -20C to + 90C Various -20C to + 75C Current: 4 20 mA Simulators and energy -20C to + 120C

Main features

High precision Several available output signals  Long working life thanks to the contactless construction  Hard environmental conditions (shock, vibrations) and high working frequencies High compatibility with high magnetic fields

Long working life   Good price/  High precision thanks to the Compact construction performance ratio contactless  Compact construction  Rugged execution construction  Mechanical contact without external Compact construction between the wiper overall dimension  High resistance at and the resistive track high temperatures

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CKA Atex cylinders

CKA cylinders are designed to work in presence of explosive gas or dust, according to ATEX 94/9/EC directive, Ex II 2GD ck IIC T6 zones 1, 2, 21, 22, being unable to involve the selfignition of the surrounding atmosphere. ATEX cylinders can be supplied with ex-proof proximity sensors or rod position transducer, ATEX certified

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ATEX cylinders

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ATEX servocylinder

CNX stainless steel cylinders

CNX cylinders are made with high quality stainless steel to ensure high resistance to corrosive environments and/or for use with aggressive fluids like HFA water based or just pure water. They are ideally suited for a variety of applications including: Pharmaceutical, Marine, Military, Waste Management, Offshore and Chemical
Mechanical properties Rm min Rs min
[MPa] [MPa]

Material AISI 316L AISI 316L A4 70 AISI 431 AISI 420 AISI 630 (17-4 ph)

Cylinder component housing and heads screws piston and rod Spherical bearing of style S housing and rod (on request)

Corrosion resistance >1200 h >1200 h >600 h <100 h >1000 h

450 700 800 700 860

195 450 600 500 724

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CNX stainless steel cylinder

Anticorrosion treatments
Rods Ni + Ch plating Nickel + Chrome plating increases the rod corrosion resistance up to 1000 h in neutral salt spray with rating 10 according to ISO 10289. Thickness: 30 m Nickel + 20 m Chrome Rods ceramic coating Ceramic treatment consists of a multilayer coating applied on the rod to grant excellent corrosion resistance in harsh environment such as petrochemical, military and railways. Cylinders Geomet treatment Geomet treatment provides a corrosion protection > 1000 h in neutral salt spray and improves the corrosion resistance of painting. Thickness: 8-10 m

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Rod with Ni + Ch plating 

26 Rod with ceramic coating

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Geomet treatment

High performance sealing system

G0 Sealing system - up to 15 Hz G0 sealing system - PTFE with mineral fiber to perform good sliding and low wear at up to 15Hz working frequencies G9 Sealing system - Low friction G9 sealing system - special polymer compound with high resistance to scratch and extrusion performs heavy duty applications with very low stick-slip 28 G0 sealing system 29 G9 sealing system 13

Special cylinders
The succesful experiences in several sectors such as steel industry, foundry, naval & marine, military, plastic injection, machine tools, etc. witness the Atos ability to develop special cylinders according to any application requirement. Atos cylinders can be supplied with naval certifications such as DNV, Bureau Veritas, ABS, Rina, etc.

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Naval

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Military

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Hazardous area

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Railways

34  Avionic

DVC designer
DVC is an easy to use tool for quick selection of hydraulic cylinders & servocylinders and following insertion in plans CAD of machines and industrial installation. Main functionalities: 2  D & 3D drawing for any CAD system  Visualization of cylinder for installation Information on variants and options Automatic offer & order forms
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development

Testing benches

Method

R&D department is equipped with automatic testing benches with high accuracy acquisition systems:  cushioning testing bench: to optimize the cushioning profile ensuring top damping effect friction testing bench: to develop special sealing system for any operating  condition Research & development fatigue testing bench: to predict the cylinders expected life with high  Atos R&D department is equipped with automatic testing benches with high accufrequency tests racy acquisition systems to improve performance and reliability of standard compo-

Atos R&D department is equipped with automatic testing benches with high accuracy acquisition systems to improve performance and reliability of standard components and to help technical office on the design of hydraulic cylinders suited to the specific customer requirements: Cushioning testing bench: it allows to optimize the cushioning profile ensuring top damping effect for the best cylinder reliability Friction testing bench: it has been designed with the cooperation of The Politecnic of Turin to measure sealing friction for several operating conditions The valuable know-how of Atos R&D department is supported by simulations softwares which allow to constantly improve the design of the cylinders targeting the best reliability and strongest execution: FEM and Fluidodynamic software.

Research & Development

loads with high quire a careful d strength which itical part. FEM ct the expected nsure the stronific application.

Simulation softwares
Fluidodynamic simulations Critical applications (i.e. high speed and short cushioning strokes) require an accurate cushioning design to ensure safety application. Atos technical department uses fluidodynamic 37 RED department simulation softwares to design the best cushion profile according to the customer requirements
cushionings
intermediate & different rods
100.000

nents and to help technical office on the design of hydraulic cylinders suited to the specific customer requirements: Cushioning testing bench: it allows to optimize the cushioning profile ensuring top damping effect for the best cylinder reliability FEM - Finite Method Friction testing Element bench: it has been designed with the cooperation of The Politecnic of Turin to measure sealing forwith several operating conditions Alternate push and pullfriction loads high working frequencies The valuable know-how of Atos R&D supported by simulations softrequire a careful analisys ofdepartment the rod is thread strength which is wares which allowmax to constantly improve design of the cylinders targeting the the cylinders critical part.the FEM software allows to predict best reliability and strongest execution: FEM and Fluidodynamic software.

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R&D department

lations

FEM - Finite Element Method

Alternate push and pull loads with high working frequencies require a careful analisys of the rod thread strength which is the cylinders max critical part. FEM software allows to predict the expected rod service life and to ensure the strongest design for any specific application.

its expected service life and to ensure the strongest possible resistance
rods strength
100.000 10.000

Emax [J] - log scale

high speed and require an accun in order to evaof these safety ment is provided ation software to profile according ents.

1.000

pressure - bar

10.000

1.000

100 10 1 0 20 40 60 80 100 120

100 10 1 0 20 40 60 80 100 120

working pressure - bar

Fluidodynamic simulations
Critical applications (i.e. high speed and cushioning strokes) require an accuDVC is a smart software for fastshort and efficient design of ISO ratecodes cushioning evaluation standard hydraulic cylinders. The assisted selec-in order to evaluate the effectiveness of these safety tion and the DVC cylinders sizing tool drive step by step devices. department is provided the user to identify the best cylinder forTechnical each application.

expected life - cycles

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cylinders & servocylinders

Atos spa
21018 Sesto Calende - Italy - Fax +39 0331 920005 - Tel +39 0331 922078 - info@atos.com - www.atos.com
TC12-1/E

41122 Modena - Italy - Fax +39 059 253346 - Tel +39 059 250550 - infocylinder@atos.com

Cylinders Division