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Hydraulic Cylinders and Cylinder Systems for Mobile Hydraulics

Production capabilities: zCylinder strokes up to 12,000 mm zPiston diameters up to 600 mm zDifferential cylinders zSynchronising cylinders zPlunger cylinders z Telescopic cylinders

Your Partner for Expertise. For cylinders and cylinder systems in mobile applications

Engineering expertise

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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 special-purpose vehicles.

Surface treatment processes

Lightweight

Functional safety – integrated sensors

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 zStructural analysis zNon-linear stability calculations zStructural durability analysis

zElectroplating zHigh-speed flame spraying and plasma spraying (metallic and ceramic coatings) z Induction melting of compound layers z Laser-welded and plasma-welded layers zCustomised paint finishes (corrosivity categories up to C5-M)

zWeight-optimisation zUse of high-strength steel materials zUse of light metal and fibre-composite materials

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 - ValvesSupport provided throughout, from risk analysis to certified machine function

EN 954-1 EN 13849-1

Machinery industry(electronics, hydraulics, pneumatics, mechanics)

IEC 61508IEC 62061

Development / design / strength calculation / testing

Cylinder solutions for all customer requirement

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At a glance

Telescopic systems

Boom, outrigger and special cylinders

zSingle-cylinder telescopic systems zSecuring locking system z Telescopic guide system zController

zWeight-optimised, space-saving design z Integrated valve technology and sensors

Mining and excavator cylinders

z For high dynamic loads zStructurally durable design

Suspension and accumulator cylinders

zCylinder-integrated accumulators zCombined cylinder/accumulator solution zSelf-supporting suspension struts

CNC lathe (12 m turning length) Automated submerged-arc welding system

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Your Partner for Expertise. For cylinders and cylinder systems in mobile applications

Cylinders for mobile technology. Light. Compact. System-based.

Production expertise

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Manufacturing techniques

Assembly and test bench

Paint application

Quality assurance

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

zCleaning and cylinder-assembly equipment zPLC-controlled hydraulic test benches for test pressures up to 1200 bar z Function and fatigue test benches

Cutting-edge paint technology for protection against wear and corrosion.

zSandblasting zCleaning zPainting zDrying

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.

Control and display

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z Telescopic guide system adapted to suit specific cranes zReliable, flexible HY-TTC 90 controller, certified to ISO 13849 zUniversal mobile display with integrated HY-eVision controller zCustomised control and visualisation software based on standard modules

Advantages and features: zComplete telescopic system package including control zSpecific interface programming zCustomised visualisation zOn-site commissioning support

Controllers and visualisation

Functional SafetyPL d SIL 2

Functional SafetyPL d SIL 2

Flexible HY-TTC 90 mobile controller

Universal mobile display with integrated HY-eVision controller

Flexible HY-TTC 500 mobile controller

Telescopic systems for mobile cranes

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Telescopic systems

Advantages and features: zComplete hydraulic/mechanical/electric system from a single source z Flexible cylinder sizing zCylinder and SLU produced to customer specifications or our own design zMinimal cylinder weight

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:

zDouble-acting hydraulic cylinder in lightweight design zGuide frame zSecuring locking unit (SLU) zHydraulic accumulator unit including valve control z Internal oil feed z Telescopic boom and position detection zPosition sensor system (optional)

In addition to customised systems, a system with the in-house developed SLU is available.Operating pressures: up to 350 barStroke: up to 12,000 mm

Securing locking unit – base mounted

Telematic system

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Cylinders for vehicle outriggers

Steering and suspension cylinders

Benefits and special features: zOutrigger cylinder for static pressures of up to 600 bar with integrated valve technology zExtension cylinder, single- and multi-stage zComplete cylinder systems for special-purpose vehicles and crane outriggers zCorrosion-resistant piston-rod coatings

Benefits and special features: z Integration of accumulator z Low-friction design z Integrated end position damping z Integrated position sensor technology

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).

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.The suspension cylinders can be supplied with accumulators integrated into the cylinder as well as external accumulators. In addition to offering cylinders as components, HYDAC also manufactures complete suspension and steering systems.

Outrigger cylinder for mobile crane with special mounting

Two-stage horizontal cylinder for outrigger

Steering cylinder with integrated position sensors

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Boom, outrigger and special cylinders

Boom cylinder

Special cylinders for cranes

Benefits and special features: z Lightweight design zHigh-strength materials used zSpecial seals prevent any leakage z Integration of valve technology zStructurally durable design

Benefits and special features: zWeight-optimised design zHigh-strength materials used z Integrated valve technology z Integrated anti-rotation piston rod

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.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.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.

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.

Lightweight boom cylinder for telescopic crane

Counterweight cylinder with integrated valve technology

Mast fall-back prevention cylinder with integrated valves, integral tanks and anti-rotation

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Road construction machinery

Mobile mining machines

Benefits and special features: zVibration-resistant design zSpecial sealing systems z Integration of position sensor technology z Integration of valve technology

Benefits and special features: zRobust design zSpecial coatings zSpecial sealing systems z Integration of position sensor technology z Integration of valve technology

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.

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.

Lift cylinder with integrated oil feed

Expansion cylinder for tunnel boring machine

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Construction machinery and mining

Excavator cylinders

Rotary joints

Benefits and special features: zRobust design for dynamic application zStructurally durable design for high cycle rates z Integrated position sensor technology

Benefits and special features: zUp to 16 ports zUp to 420 bar zPiston coating for maximum service life z Integration of compressed-air and electrical feed

Cylinders used in excavators, particularly large excavators and mining excavators, have to demonstrate a high degree of robustness and availability.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.

For excavators, cranes and other construction machinery, Hydrosaar offers customised rotary joints.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.

Jaw cylinder for mining excavator

Boom cylinder with integrated position sensor system

Hydraulic rotary joint for large excavator, 16-port

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Active heave compensation Real-world examples

Benefits and special features: zCombined cylinder/accumulator system for active heave compensation zReduced drive power and operating costs zDesigned for specific application z Low-temperature design (to -40 °C)

Action/strategies: zEnergy recovery zDownsizing zBoost operation

Benefits: zReduced fuel consumption zProductivity increase zNoise control

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.

Cylinder for active heave compensation system

Working load

Base load

Compensation force

Residual load

Active heave compensation: Material handler

Stroke

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Suspension and accumulator cylinders

Suspension-damper cylinders

Benefits and special features: zCylinders with integrated or external hydraulic accumulators zOpen and closed hydraulic systems zAdjustable damping characteristics zDesigned according to Pressure Equipment Directive zSelf-supporting design possible zPiston-rod coating tailored to suit operating conditions z Low-temperature design (to -40 °C)

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.

Suspension cylinder with integrated accumulator

Suspension characteristics, suspension damper cylinder

275

250

225

200

175

150

125

100

75

50

25

00 10 20 30 40 50 60 70 80

Distance in mm

Quasi-statistical suspension characteristics, ∆z = ±35 mm, f = 0.5 Hz

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Global Presence. Local Expertise. www.hydac.com

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HYDAC Headquarters

HYDAC Companies

HYDAC Sales and Service Partners

Hirschbachstr. 7 66280 Sulzbach/Saar Germany

Tel.: +49 6897 509-9700 Fax: +49 6897 509-9791

Email: info@hydrosaar.de Internet: www.hydac.com

Contact HYDAC INTERNATIONAL

GMBH