Flex Cam
Hydrauliccylindersandtoolslides fortoolandmould-makingand machineryconstruction
Introduction
Description
Page
5-6
6-7
8
9
10
11- 14
15- 47
Stroke rate/Capacityand output Funktion PowerUnit/CamUnitcombinations Selecting the components
Dimensions and Order No
Cam Units ForceCylinders 15-40-60-90-150kN ForceCylinderswithbaseplate 15-40-60-90-150kN CompactCams 15-40-60-90-150 kN PowerUnits 15-40-60-90-150 kN Flange Cam Electric hydraulic pump Electric hydraulic pump Quick-release couplings
16-22-30-36-42
17-23-31-37-43
18-34-32-38-44
20-28-34-40-46 26-27 49-51 50 51
Accessories
53- 70
Connecting hoses
Threadedcouplings
Charging and control fitting
Oil filling unit
Assemblytool
Control fitings
Compound threaded joints
Test hosesand couplings Pressure switches
Sensor mounting kit
Inductive proximity switch/Connection cable
TopmountingforFlange Cam
Safetymodule
Safetylabel
54-55
54-58
59
60
61
62
63
64-65
66
67
68
69
70
Typicalinstallationsformonitoringprocesssafety Monitoring Typicalapplications
71- 75
72-75
77- 81
82 -83
84 - 85
FIBRO-The latest technology with a tradition of service Representatives
Flex Cam
General
SystemsafetyreliabilityandfunctionalitycanbeensuredbysupplyingFlBROwiththeaplicationdataanddrawingsofthe installationarrangementsforchecking.
Please note that the numberof the threadedconnections and the hose lengths forinstallation in the system must be determined.
4
Assembly,commissioning,maintenanceand servicing of the Flex Camsystemrequire special knowledge andmayonlybecarriedoutbyFlBROtrained,specialistpersonnel.
Youcanorderthework tobecarriedoutbyaFIBROcustomerserviceengineer,tobeinvoicedinaccordancewithour installationtariff.
Justcontactustoschedule itforyou.
We shall be pleased to answerany technical queries you may have,now orat any time in the future.
V
As the Flex Cam systemwhich are specially made,we recommend that you keep reserve systems instockto avoid the riskof delaywhen the need arises.
Introduction
The hydraulic cam system is the ideal com-ponent for executing linearmotionsatanypoint in theavailable space.
The system is increasinglyatng used in tool making,in particular,to drive drawing,moulding,cuttingand drilling operationswhere conventional slides cannotbeused due to lack of space or inconvenient position.
The working motion is generated by the cam unit (e.g. the working cylinder),which can be installed inanyposition in theavailablespace.
The cam unit is controlled by a driving cylinder which,in turn,is activatedby thestrokemotionofapress,for example.
The link between the two is provided bya hydraulic hose inwhich the volume of oil in the powerunit is displaced to the cam unit.
Description
Power Unit
The Power Unit consists of the following components:
·PowerCylinder
·Accumulator
·Adapter plate
ThePower Cylinderis filled with oil at one end,while the machine thatexecutes thestroke isattheoppositeend.
The accumulator is charged with nitrogen gas at one end. In the idle state,the base of thepiston restson the Accumulator,relieving thepressureonthesystem.
Theadapter plate connects the Power Cylinder to the Accumulatorand Force Cylinder.
Inthestandardversion,thecapacityoftheaccumulatoris matchedtothetotaldisplacementvolumeof thePower Cylinder. It is thus of the same heightas the piston rod. The integral rupture protectiondevice opensat517 bar.
ThePowerUnitisalsoavailablewithaseparatePower Cylinderand Accumulator.
Cam Units
Thereare3typesofCamUnits: ·Force Cylinder2018.30./40./50./60. ·Compact Cam 2018.11. ·Flange Cam 2018.12.
Force Cylinder2018.30./40./50./60.
Design
Theaccumulator is charged with nitrogen gasat one end (20-40bar).ThevolumeofoildisplacedfromthePower Unitacts on the other end when the Power Unit is pressurised.The Force Cylinder then extends.The retractionmotion is generatedbythe nitrogengaswhen the pressure is relieved on the stroke side of the Power Cylinder.
The displacement length of the Force Cylinder is twice as longas the permissible nominal displacement length.The unuseddisplacementcapacityisneededasa compartment for the pressurised nitrogen gas inorder to return thestroke.
Applications
TheForce Cylinderisdesigned to drivean individual tool component (e.g.a slide).
Thenominal stroke of the Force Cylinder may be limited byexternalstops.Asastandardthestroke'sendposition islimitedbyaninternalstopaccordingtostrokelength. The Force Cylinder isnot guidedand therefore cannot absorbanysideloads.Thetoolcomponentsthemselves must be guided.
4 SideImdilactingontheForceCylinderleadto
Whenattachingaccessories,becarefulto ensure that the axesare linedupcorrectlytoavoidtransverseforces duringthestroke.Couplingpinsorsimilaraccessories must be used for the connection as there must be no rigid connectionbetweenthepistonof theForce Cylinderand the tool components.
Compact Cam 2018.11.
Design
The Power Cylinderstarts the pistonrod of the Compact Cammovingwhen pressurised.
The slide is returned by external gassprings.Two pillars with guideways prevent the tool holderplate rotating.The clearance in the guidesis 0 . 0 1 rm { -- } 0 . 0 3 \ : {mm }
Applications
The Compact Cam is suitable for hole punching operations involvingno transverse forces.The Compact Camisguidedandhasaninternalstop.Punchescan be mounted directly on the tool holderplate.
4 Side loedfantheCompactCamwllead
In cutting operations with asmall cutting clearance and asymmetrical cutting forcesa guide bolstershouldbe provi-ded,withanexternal guide toabsorb the lateral forces.Aswith the Force Cylinder,couplingpins must be used for the connection between the slide and the external guide (uncoupling). The Compact Camis attachedby4fixingscrews.Afeatherkeygrooveabsorbs the cutting forces. It is positioned by means of two pilot holes.
Flange Cam 2018.12.
Design
TheFlange Camconstructionisthesameas the constructionoftheCompactCam.ThePowerCylinder starts the piston rod of the Flange Cam moving when pressurised.The slide is returnedby external gassprings. Two pillarswith guidewaysprevent the tool holderplate rotating.Theclearance in the guidesis 0 . 0 1 - 0 . 0 3 \ : {mm } The tool holderplate issupportedbyarolleranda supportplatetoabsorb lateral forces.
Applications
TheFlangeCamissuitableforworkoperationswith lateral forces (e.g.bend up,sliding).The Compact Cam is guidedwithan integratedstop.Punchescanbemounted directlyon the tool holderplate.
4 Argvideorteritxeraldesouldbe asymmetrical forces.
TheFlange Cam isattachedby4fixingscrews.A feather keygrooveabsorbs the bending forces.It ispositioned by means of two pilot holes.
Alternativedrive
Foroperating theCamUnitelectricallypowered Hydraulic pump units can be used (see page 5O).The max.working pressure must not exceed 150 bar.The max.speeds listedonpage8mustnotbeexceeded.
Charging fittings
Nitrogen gas:The Accumulator and Cam Unit can be chargedwith the gas spring filling charge 2480.0o.32.21.
Hydraulic system:The system is filled and vented using theoil fillingunit 2018.00.30.
Filling and venting of thesystem is described in detail in the user manual supplied with the system.
Hydraulicconnection
See also pages 51-58
User-friendly,flexiblehigh-pressurehosesare idealforthe hydraulic connections (see page 50).
Aspace-saving alternative is to use system hydraulic pipes.
The same screwed couplingsare used for both hosesand pipes.
The hose length should not exceed 2 0 0 0 \mathsf {mm } Thisis important to ensurea constant build-up of pressure and -evenmore importantly-tominimise impact during cuttingwithoutasignificant pressure build-up.
Thecouplingsshouldbedesignedforatleast3oobar nominal pressure and 1ooo bar rupture pressure.
This is essential if the connection is to be sufficiently rigid and forthe rupture protectiondeviceto operateat 517 bar.
Quick-releasecouplings forhydraulic hoses
We recommend that you use quick-release couplings to join the hydraulic hoses.
Benefits:
·Thesystemcanbefilledandventedunderoptimum con-ditionswhenoff the tool,eitheratFlBRO oron site. ·If the tool has to be assembled or dismantled, the hydraulic hoseconnectingthePower Unitand the Cam Unit is disconnected using the quick-release coupling. It is thus not necessary to dismantle the hoses,drain and refill the oil and vent the system,which keeps costs down.
Forlayout purposes,the dimensions of the commonly usedthreadedcouplingsand hosesareshownon pages 51,54-58
Leaksandoil level display
The experience we have gained in manufacturing gas springsenablesustoselectthemostsuitableseals. The result isan effective and long-lasting seal.
The connecting line can beassembled with no leaks, usingavailablematerialsandwithcareful installation.
If anoil leakdoes occur, itwill becompensated short termbytheovertravelvolumeintheAccumulator.
TheAccumulatorandPowerCylinderareof thesame height,soany loss of oil from the system will be manifestedbyadifference in height.
Flex Cam
Strokerate
Thestroke rateisdependentontheminimumflow opening,thevolume of oiland theworkingand return pressures.Theconnectingopeningsallowaworking stroke rate of up to 0 . 8 ~ \mathsf { m / s } .Although this is limitedby the extent towhichthesystem heatsupdue to the high stroke rates.The system temperatureshould not exceed 6 0 ^ { \circ } \mathsf { C }
Asthevolumeofthehydraulicoil increaseswhenthe system temperature rises,thecamunitno longerreturns completelyto itsstrokestartingpositiondue to the oil expansion.Forthis reason,astroke reservemust be compliedwithat the start of thestroke (idle stroke).
4 Theminid 6 \min estrekeingouldbenumwernf strokes.
Safetyinstructions
If the layout of the system gives the Force Cylinderan excessivedisplacementvolumeduetoexcessovertravel and/orseizingofthecylinder,thepressureinthesystem canexceed theadmissiblevalue of 280 bar.In critical situations,this effect will be counteracted by the opening ofarupturevalveat517bar.
The couplings are designed fora nominal pressure of 300barand 1ooo bar rupture pressure.
On the gas side,the Accumulator is pressurised at 150 bar and is subject to Pressure Equipment Directive 97/23/EC.
Tomonitor safety during the process,we recommend installinga control fittingasanadditional check on the gas side-see range of accessories.
Capacity and output
The forces listed intable1belowareapplicable for the following nitrogen gas pressures:
Accumulator 150bar Force Cylinder 20bar Compact Cam
2018.11.01500.and2018.11.04000.
Gas spring 2480.21.and.23.00000. 180bar 2018.11.06000.
Gas spring2487.12.00350. 180bar Compact Cam
2018.11.09000.
Gas spring2480.12.00500. 150bar 2018.11.15000.
Gas spring 2487.12.00750. 150 bar Flange Cam
2018.12.04000.049
Gasspring2480.21.bzw..23.00000. 180bar
Comments
The Accumulator and the Force Cylinder are pressure vesselsandassucharesubjecttothePressure Equipment Directive 97/23/EC.
During cutting and hole punching operations the nominal force of the Compact Cam should only be utilised up to 7 5 % tominimise impact during cuting which is reinforced bythe Accumulator. Impact during cutting can be reducedbypolished tool edges (e.g.roof shape) and so downtime can be reduced.
| Force Cylinders | Compact Cams | Flange Cams 2018.12. | Power Unit 2018.20 | ||||||
| Description Force(magnitude) | KN | 2018.30. 15 406090 | 2018.11 15 4060 | 90 150 | 40 15 | 40 60 90 150 | |||
| Initialrestoringforce | KN | 581321 | 150 247 | 10 | 15 | 4 | - - 二 - | ||
| Minimum gaspressure | bar | 2 10 | 125 | 105 | 125 | 50 | |||
| Maximumgaspressure | bar | 40 | 180 | 150 | 180 | 180 | |||
| Strokelength | mm | 25,50,100 | 24,49,99* | 49 | 35**,60**,110**,160**(1) | ||||
| Maximumspeed | m/s 0,8 | 0,8 | 0.8 | 0,8 | |||||
| Maximumrestoringspeedm/s | 0,8 | 0,8 | 0.8 | 0,8 | |||||
| Maximumfrequency | Strokes/min | 30 | 60 | 30 | 60 | 60 | 603030 | ||
| Ambienttemperature | ℃ | 10-40 | 10-40 | 10-40 | 10-40 | ||||
Table1:Technical data
Values other than those specified in theabove table may beacceptedundercertaincircumstancesorifdifferent stroke lengths,speedsand frequenciesare combined.
Function
Theindividual components of the Flex Cam System describedabove interactas follows:
① The Power Cylinder isactuated by the stroke of the press. 一
② Once the pressure build-up in the Flex Cam exceeds the preset pressure in the Force Cylinder,the Force Cylinder extends.
③ When the Force Cylinder reaches its working position, thepressure in the system rises to match the pressure intheAccumulator.Therestofthedisplacedvolumeof oil isthen heldin the Accumulator (Power Cylinder overtravelsbyapprox. 3 - 1 0 \mathsf {mm } 一
④ This overtravel is essential since it ensures that a constant contact pressure is builtup duringeach stroke.
Atthe same time the pressure on the Power Cylinder is relieved (returntravelof thepress),theForceCylinder is reset by the nitrogen gas.
Pressureratiosinthesystem
The above diagram shows the oil pressure build-up during the work cycle.Before the working motion, the oil-system is pressureless.When the Power Cylinder is actuated,the oil pressure rises tothe preset gas pressure in the Cam Unit.As the Force Cylinder continues to travel,the volumeof gasis further compressed until thework operation isexecuted.At the sametime,theback-pressureinthesystemrisesdueto the punching operation,for example.Once the operation hasended,thePowerCylindercontinuesasfarasthe end positionof the Force Cylinder.This ensures that the excessvolumeofoil is fullyabsorbedbythe Accumulator.Atthesametime,theoil pressurerisesto match the charging pressure in the Accumulator.
If a malfunction occurs in the tool part during system travelandblocksthetraveloftheCamUnit,all the displacedoil is held in the Accumulator.Theoil pressure increasesuntil itequals thatof the compressed nitrogen in the Accumulator.
Thesystemisprotectedbyanintegral ruptureprotection device in the Accumulatorwhich opensat517 bar to ventthe nitrogen.The resulting systemsecurity protects the tool from damage by the Flex Cam.
Possible combinations PowerUnitwithCamUnit
Cam Unit leading
If astrokeof the Cam Unit isrequired before the tool actually reaches its workingposition,thiscan beachievedbyincorporatingagasspring. Thepressstrokeactuatesagasspringwhich,inturn,actuatesthe PowerUnit,since itsprestressing force ishigherthanthenominal force of the Power Unit.
When the Cam Unit reaches its end position,the drive (press) overtravel iscompensatedby the retractingpistonrod of the gasspring.Aspring contactwashertransmitsthepressureof thegasspringtothe supporting tubewhenthePowerUnitreachesitsend position.
Several Cam Units driven asynchronously
SeveralCamUnitscanbedrivenbyacommonPowerUnit.The individual CamUnitsshould not,however,bemechanicallyconnected to oneanother since the feedrates cannot be totally synchronised due to thedifferent connection lengths (system losses) and restoring forces.
Several Cam Units drivensynchronously
Synchronous operation canbe achieved by using two systems of the samedimensions,although thisapplication requires the restoring force ofthe individual CamUnits to beequal,aswell.
One ormore Cam Units driven with delay
Atimedelay,and thusa variableworkingsequence for the Cam Units, canbeachievedbycombiningtwodifferentstrokes.ThefirstPower Unit tobeactuated executesthe firststep.Asthe Cam Unitmovesbeyond its end position,the excess oil is displaced into the Accumulator (not shownin thediagram).Thesecond Power Unit can thenenter the working sequenceas required.
Variablespeed/forcedrive
Theforcesor travel speedscan be combined as required byvarying the ratiobetweenPowerUnitsizesandCamUnitsizes.Themaximum travelling speed should not exceed 0 . 8 \mathsf { m / s } ,however.
Transmission ratios inuse
Transmissionorreduction ratioscan beexpressed in fourdifferent ways:
a) Force
b) Speeds of the individual Cam Units
C) Press travelspeedto Cam Unittravel speed
d) Stroke lengths
Transmissionratios
The nominal transmission ratio of 1:1 is normally used throughout the system. Theratiocanvary,however,according to thecombination (and number) of Power Unitsand Cam Units used (see table on page 12).
Selecting the components
Thecomponent sizesareexplainedstepbystep belowwith regard to theforcesrequired,stroke lengthand thenumberof operations.
Step1:Size of the Cam Unit
Calculate the force required for the operationto be carried out.The Cam Unitused should provide sufficient force to execute the operation.If the forcerequiredcannotbe preciselycalculated,werecommend that you usealargerCamUnit.
| Force required (kN) | Cam Unit |
| 0-15 | 2018..01500. |
| 15-40 | 2018..04000. |
| 40-60 | 2018..06000. |
| 60-90 | 2018..09000. |
| 90-150 | 2018..15000. |
Force required: KN Cam Unit size:
Example: If the force required is22kN,thena40kNCam Unit should be used.Cam Unit2018..04000.
Step2:Cam Unit stroke length
Determine the Cam Unit stroke required to execute the operation in the tool.Use the Cam Unit with the shortest possible stroke,but remember thatthe tool must have sufficient space for theworkpiece.
| Required stroke length (mm) | Max.stroke length of Cam Unit (mm) | Part number |
| 0-25 | 25(24)*** | 2018...025* |
| 25-50 | 50 (49)*** | 2018...050* |
| 50-100 | 100(99)***** | 2018...100* |
\*)2018.11..024/049/099
\*\*)Thisstroke lengthdoesnotapplyto Compact Cam 2018.11.01500.
\*\*\*) Compact cam
StrokelengthofCamUnit: mm
Example:If thestrokelengthrequiredis35mm,useaCamUnitwitha stroke lengthof 5 0 ~ \mathsf {mm }
Step3:OrdernumberoftheCamUnit
Selectthe Cam Unitaccording to the type of operationto be performed
Seealso pages6,7,12-14 Compact Cam:2018.11.. Flange Cam:2018.12.04000.049 Force Cylinder:2018.30..
Example:Theorder number for the Compact Cam is 2018.11.04000.049
Flex Cam
| Nom. | Power Unit | Power Unit | Power Unit | Power Unit | ||||||||||||
| Cam Unit force (kN) | stroke (mm) | No. | 15kNSU | TR | 40 kN | SU | TR | 60kN | SU | TR | 90kN | SU | TR150 kN | SU | TR | |
| 15 | 25 | 1 | 035 | 35 1,0 | 035 | 20 | 2.5 | 035 | 16 | 4,0 | 035 | 14 | 6.3 | 035 | 13 | 9,8 |
| 25 | 2 | 060 | 60 0,5 | 035 | 30 | 1,5 | 035 | 23 | 2,0 | 035 | 18 | 3,1 | 035 | 15 | 4,9 | |
| 25 | 3 | 11085 | 0,3 | 060 | 40 | 0,8 | 035 | 29 | 1,3 | 035 | 22 | 2,1 | 035 | 18 | 3,3 | |
| 060 60 | ||||||||||||||||
| 50 | 1 | 1,0 | 035 | 302.5 | 035 | 23 | 4,0 | 035 | 18 | 6.3035 | 15 | 9,8 | ||||
| 50 | 2 | 110110 | 0,5 | 060 110 | 50 | 1,2 | 035 | 35 | 2,0 | 035 | 26 | 3,1 | 035 | 20 | 4,9 | |
| 50 | 3 | 70 | 0,8 | 060 | 48 | 1,3 | 035 | 34 | 2,1 | 035 | 25 | 3, | ||||
| 100 | 1 110 | 110 | 1,0 | 060 | 50 | 2,5 | 035 | 35 | 4,0 | 035 | ||||||
| 100 | 2 | 110 | 91 | 1,2 | 060 | 60 | 2,0 | 060 | 26 | 6,3 | 035 | 20 | 9,8 | |||
| 100 | 3 | 160 | 131 | 0.8 | 110 | 85 | 42 | 3,1 | 035 | 30 | 4,9 | |||||
| 1,3 | 060 | 58 | 2,1 | 060 | 41 | 3,3 | ||||||||||
| 150 | 1 | 1601601,0 | 110 | 702.5060 | 484.0 | 060 | ||||||||||
| 150 | 2 | 160 | 131 | 1,2 | 110 | 85 | 2,0 | 060 | 58 | 346.3035 3,1 | 25 | 9.8 | ||||
| 150 | 3 | 160 | 123 | 1,3 | 110 | 822,1060 | 060 | 41 | 4,9 | |||||||
| 72 | 0,4 | 56 | 3,3 | |||||||||||||
| 40 | 25 | 1 110 | 035 | 35 | 1,0 | 035 | 26 | 1,6 | 035 | 20 | 2,5 | 035 | 16 | 3,9 | ||
| 25 | 2 | 060 | 600.5 | 060 | 41 | 0.8 | 035 | 30 | 1,3 | 035 | 23 | 2,0 | ||||
| 25 | 3 | 110 | 850, | 060 | 57 | 0,5 | 060 | 40 | 0,8 | 035 | 29 | 1.3 | ||||
| 1 | 060 | 60 | 1,0 | 060 | 41 | |||||||||||
| 50 | 2 | 110 | 110 | 1,6 | 035 | 30 | 2.5 | 035 | 23 | 3.9 | ||||||
| 50 | 3 | 160 | 1600.3 | 0,5 | 110 110 | 72 | 0,8 | 060 | 50 | 1,3 | 035 | 35 | 2,0 | |||
| 50 | 1030,5 | 110 | 70 | 0,8060 | 48 | 1,3 | ||||||||||
| 100 | 1 | 110 | 110 | 1,0 | 110 | 72 | 1,6 | 060 | 50 | 2.5035 | ||||||
| 100 | 2 | 160 | 134 | 0,8 | 110 | 89 | 1,3 | 060 | 35 61 | 3,9 2,0 | ||||||
| 100 3 |
Step 4a Sizeand stroke of thePower Unit
Followstep4aifonetothreeCamUnitsofthesamesizeare connected toa given PowerUnit.IfdifferentCamUnitsareconnected toaPower Unit, thenstep4b should beused.
SelectthePowerUnitfromthe followingtable.Thetableshouldbe read inthe following order:Cam Unit-force-stroke-number-Power Unit -stroke length.We recommend thatnomore than three Cam Unitsbe connectedtoasinglePowerUnit.
Make sure that you do not exceed the maximum Cam Unit stroke speed ( 0 . 8 ~ \mathsf { m / s } ) :
See also the following examples:
Example1(Fig.1):A Power Unit 2018.20.04000.060 is provided as standard fora Compact Cam2018.11.04000.049.Thenominalstrokeof thePowerUnitis 6 0 ~ \mathsf {mm } .Thetransmissionratiois1:1.Thestrokeof the Compact Cam is thus performedatthe same speedas the press.
Example2(Fig.2):Ifapressstrokeof just 3 0 ~ \mathsf {mm } canbeused toexecute theoperation,thena largerPowerUnit2018.20.09000.035shouldbe used for theCam Unit2018.11.04000.049.ThePowerUnitstrokeused is 3 0 ~ \mathsf {mm } thetransmissionratio is2.5.If thepress speed is 0 . 3 ~ { m / s } then the Cam Unitstroke speed obtained is 2 . 5 x 0 . 3 ~ { { m } / { s } = 0 . 7 5 ~ { { m } / { s } } }
Thestroke used by Power Unitand Cam Unit canbe perfectlymatched toanyspecialconstraintsassociatedwiththetool.
Forsomeapplications,thespeedof theCam Unitmustbe increased in proportion to the pressspeed.
4 IfaCamUntsetrn
Example3(Fig.3):APower Unit 2018.20.04000.110 can be used with two Compact Cams2018.11.04000.049 anda useful press strokeof 1 1 0 \mathsf {mm } .ThePowerUnitstrokeusedis 1 1 0 \mathsf {mm } andthe transmission ratio is 0.5.
If the press speed is 0 . 3 ~ \mathsf { m / s } ,then the mean Cam Unit stroke speed obtained is 0 . 5 x 0 . 3 = 0 . 1 5 { m } / { s } 美
Selection flowchart
PowerUnit \mathbf { \sigma } = \mathbf { \sigma } Nominalworkingforce/nominalstroke \phantom { - } + 1 0 \mathsf {mm } overtravel
SU \ c = Workingstroke(strokeactuallyused) ^ + 10mm
TR = Transmissionratio
Power Unit:
2018.20.
Step 4b Size and stroke of the Power Unit fordifferent CamUnitsizes
The total volume of oil in the Cam Units should be calculated using the following formula.The total volumeof oil is thesumof all thevolumes forall Cam Units.Thevolume is the product of the pistonsurfacesand strokesused.ThetotalvolumeofoilVNforthePowerUnits corresponds to the minimum volume of oil for the Cam Units (in dm3). ANisthe pistonsurfacearea in the Cam Unit (dm2) asshownin table2.
(Formula 1)
| WK AZ AK | 15kN | 40 kN | 60kN | 90kN | 150kN |
| AN(dm²) | 0,13 | 0,1 | 0,50 | 0,79 | 1,23 |
Total volume of oil of Cam Units: \mathsf { V } _ { \mathsf { N } } = dm3
| WK | = | Compact Cam | 2018.11..□ |
| AZ | = | ForceCylinder | 2018.30.□. |
| AK | = | FlangeCams | 2018.12.. |
Selecttheappropriate Power Unitfrom Table3. ThePower Unitmust supply theminimum volume of oilascalculated above.Calculate the required Power Unitstroke \mathsf { S } _ { \mathsf { G e r f } } using the following formula:
(Formula 2)
| SGerf = | [VN:VG)·SG]+10 |
| VN | TotalvolumeofoilofCamUnits |
| VG | TotalvolumeofoilofPowerUnit |
| SG | PowerUnitstroke |
| SGerf | = = PowerUnitstrokerequired |
| Stroke | Nominal | Power Unit size 2018.20 | ||||
| length | strokelengthSG15kN | 40kN | 60kN | 90kN | 150kN | |
| .035 | 25 | 0,31 | 0,078 | 0,126 | 0,196 | 0,307 |
| .060 | 50 | 0,063 | 0,156 | 0,251 | 0,393 | 0,614 |
| .110 | 100 | 0,126 | 0,312 | 0,502 | 0,785 | 1,227 |
| .160 | 150 | 0,188 | 0,468 | 0,753 | 1,178 | 1,841 |
Power Unit stroke used: SGerf = mm
Example:
Selecta PowerUnittooperatea CompactCam2018.11.01500.049and aForce Cylinder 2018.30.04000.050 with a used working stroke of just 4 0 \mathsf {mm }
| VN | = | [AWK·SWK)+(AAZ·SAz)]:100 | |
| VN | = | [(0,13·49)+(0,31·40)]:100 | (see formula1) |
| VN | = | 0,189 |
The volume of oil of theselected PowerUnit should begreaterthan0,189dm3.Forexample,the2018.20.06000.060 supplies0,251dm³.(The 2018.20.04000.110 couldalso be used) (see table3) Calculate the used stroke of the Power Unit:
| SGerf = | (VN:VG)·SG)+10 |
| SGerf = | (0,189:051)·50)+10(see formula2) |
| SGerf = | 48mm |
Intheabove example,we recommendaPower Unit 2018.20.06000.060 withaused stroke of 4 8 \mathsf {mm } .Theadmissible Cam Unit stroke speeds definedinsection9 must notbe exceeded.It shouldalso be noted that theCam Unitswill havedifferentstroke speeds if two CamUnitsare drivenbyasingle Power Unit.
Step 5
Selectappropriate hosesand screwedcouplings.Themaximum admissible hose lengthbetweenPowerUnit
and the Cam Unit is 2 0 0 0 \mathsf {mm } Thenominal hosedia
meter isdetermined onthebasisofthesizeof the PowerUnit.The hosesizeismatchedtothe flowofoil
(see page 50).
Depending on the press speed a nominal hose width smaller than the standard nominal widthmay beused (see table 4).
| PowerUnit | Nominal hose size Standard nominal width Max.speed | ||||
| 0.6m/s | 0,4m/s | ||||
| 0.8m/s DN12 | DN12 | 0.2m/s | |||
| 2018.20.01500 | DN12 | DN12 | |||
| 2018.20.04000 | DN20 DN20 | DN12 | DN12 | ||
| 2018.20.06000 | DN25 DN20 DN25 | DN20 | DN12 | ||
| 2018.20.09000 | DN25 DN32 | DN20 DN25 | DN 12 | ||
| 2018.20.15000 | DN32 | DN20 | |||
Itiseasiesttodetermine thecorrect hose length if both Power Unitand Cam Unitare installed inside the tool.
Remembertoprotectthehoseagainstsharpedgesetc.Thehose movesslightly during operation due to the pulsating oil pressure. Observe the minimum bending radius.
Dimensions and
Order No:
Cam Units Force Cylinders Compact Cam Flange Cam
Power Units
2) The cam unit no longer returns completelyto itsstrokestarting position due to the oil expansion whichisattributable to the temperature.Allowforanincreaseof 3 \min to 6mm.
3)This fastening may onlybe subjected to pressure (by support).
| Restoring force in kN*at 20 bar (max.40 bar) | ||||||
| Orderno 2018.__.01500.025 | Stroke 25 | 173 Imin | a 214 | b 192 | 1,5 Strokestart | 3.1 Stroke end |
| 2018._.01500.050 | 50 | 223 | 264 | 242 | 1,5 | 3,1 |
| 2018.__.01500.100 | 100 | 323 | 364 | 342 | 1.5 | 3.1 |
| 2018.__.01500.150 | 150 | 423 | 464 | 442 | 1,5 | 3,1 |
| *isothermic | ||||||
| Stroke | Restoring force in kN*at 20 bar (max.40 bar) | |||
| Orderno 2018.45.01500.025 | 25 | 223 Imin | Stroke start 1,5 | Strokeend 3,1 |
| 2018.45.01500.050 | 50 | 273 | 1,5 | 3,1 |
| 2018.45.01500.100 | 100 | 373 | 1,5 | 3.1 |
| 2018.45.01500.150 | 150 | 473 | 1,5 | 3,1 |
| *isothermic | ||||
Note:
1) Preferablyapply the stamp in the middle of the pistonrod.Wherenecessary,thestampcanbe placed in themarkedarea.Duringdisengaging andtrimmingoperations,anexternal guidemust beprovided inordertoabsorbthe lateral forces which occur.
2)The cam unit no longer returns completely to its strokestarting position due to the oil expansion which isattributable tothe temperature.An allowancemustbemade foranincreaseof 3 \mathsf {mm } to 6 \mathsf {mm }
| Orderno | Stroke max. | 一 | 11 | Restoring force inkNat180bar | Stroke end | |
| 2018.11.01500.010 | 10 | e 80 | 141,5 | 119,5 | Stroke start 2 | 2.6 |
| 2018.11.01500.024 | 24 | 94 | 155,5 | 133,5 | 2 | 2.6 |
| 2018.11.01500.049 | 49 | 119 | 180,5 | 158,5 | 2 | 2,6 |
2018.11.01500.___.1 Install together with measuring hose and control fitting (gasspring and nitrogen connectionare valveless).
Note:
1 ) Preferably apply the stamp in the middle of the pistonrod.Wherenecessary,thestampcanbe placedinthemarkedarea.During disengaging andtrimming operations,anexternal guide mustbeprovided inordertoabsorbthe lateral forces which occur.
2)Thecamunit no longerreturnscompletelyto itsstrokestarting positiondue to the oil expansionwhichisattributabletothe temperature.Anallowancemustbemade for anincreaseof 3 \mathsf {mm } to 6 \mathsf {mm }
| Orderno | Stroke max. | e | 一 | 11 | 12 | RestoringforceinkNat180bar Stroke start | Strokeend |
| 2018.11.01500.010.1 | 10 | 80 | 141,5 | 119,5 | 93 | 2 | 2,6 |
| 2018.11.01500.024.1 | 24 | 94 | 155,5 | 133,5 | 107 | 2 | 2,6 |
| 2018.11.01500.049.1 | 49 | 119 | 180,5 | 158,5 | 132 | 2 | 2,6 |
\*Tighten M8 fixing screw to 25 Nm
| Orderno | Stroke+101) | 一 | 11 | 12 |
| 2018.25.01500.035 | 35 | 220 | 213 | 130 |
| 2018.25.01500.060 | 60 | 270 | 264 | 180 |
| 2018.25.01500.110 | 110 | 370 | 364 | 280 |
| 2018.25.01500.160 | 160 | 470 | 464 | 380 |
2018.20.01500.
| Orderno | C | 一 | Stroke+101) |
| 2018.20.01500.035 | 185 | 220 | 35 |
| 2018.20.01500.060 | 210 | 270 | 60 |
| 2018.20.01500.110 | 260 | 370 | 110 |
| 2018.20.01500.160 | 310 | 470 | 160 |
2018.__.04000.Force Cylinder40kN
| Restoring force in kN*at 20 bar(max.40 bar) | |||||||||
| Orderno | Stroke 25 | 195 | a 246 | b 219 | 4,2 Stroke start | 8.4 Stroke end | |||
| 2018._.04000.025 2018.__.04000.050 | 50 | 245 | 296 | 269 | 4.2 | 8,4 | |||
| 2018.__.04000.100 | 100 | 345 | 396 | 369 | 4.2 | 8.4 | |||
| 2018.__.04000.150 | 150 | 445 | 496 | 469 | 4.2 | 8,4 | |||
| Order no | Stroke | Imin | Restoring force in kN*at 20 bar (max.40 bar) | Strokeend | |
| 2018.45.04000.025 | 25 | 245 | 4,2 Stroke start | 8,4 | |
| 2018.45.04000.050 | 50 | 295 | 4,2 | 8,4 | |
| 2018.45.04000.100 | 100 | 395 | 4,2 | 8,4 | |
| 2018.45.04000.150 | 150 | 495 | 4,2 | 8,4 | |
| *isothermic | |||||
Note:
1 Preferably apply the stamp in the middle of the piston rod.Wherenecessary,thestampcanbeplacedinthe markedarea.During disengagingand trimming operations,anexternal guidemustbeprovided in ordertoabsorbthe lateral forceswhichoccur.
2)The cam unit no longer returns completely to its stroke starting position due to the oil expansion which isattributabletothetemperature.Anallowancemust bemade foranincreaseof 3 \mathsf {mm } to 6 \mathsf {mm }
| 一 | Restoring force inkNat180 bar | |||||
| Orderno 2018.11.04000.024 | Stroke max. 24 | e 135 | 214 | 11 187 | Stroke start 4 | Strokeend 5,2 |
| 2018.11.04000.049 | 49 | 160 | 239 | 212 | 4 | 5,4 |
| 2018.11.04000.099 | 99 | 210 | 289 | 262 | 4 | 5,6 |
2018.11.04000.__.1
Installtgetherwithmeasuring hoseand controlfiting (gas springand nitrogenconnectionare valveless).
Duplicate nitrogen gas ports for connecting the measuring hose.
Useonly one portwhilst keeping the other one closed.
2)The cam unit no longer returns completelyto itsstrokestarting positiondue to the oil expansionwhich isattributabletothe temperature.An allowancemustbemade foran increaseof 3 \mathsf {mm } to 6 \mathsf {mm }
| Orderno | Stroke max. | e | 一 | 1 | 12 | RestoringforceinkNat180bar Stroke start | Strokeend |
| 2018.11.04000.024.1 | 24 | 135 | 214 | 187 | 112 | 4 | 5,2 |
| 2018.11.04000.049.1 | 49 | 160 | 239 | 212 | 162 | 4 | 5.2 |
| 2018.11.04000.099.1 | 99 | 210 | 289 | 262 | 237 | 4 | 5,2 |
2018.12.04000.Flange Cam40kN
| RestoringforceinkNat180bar | |||||||
| Order no | Stroke max. | Strokestrt | Strokeend | a | b | C | d |
| 2018.12.04000.049 | 49 | 4 | 5,2 | 304 | 109 | 39 | 13 |
| 2018.12.04000.099 | 99 | 4 | 5,2 | 404 | 159 | 89 | 63 |
2018.12.04000.___.1 Flange Cam 40 kNwith gasmonitoringconnection
3 {mm } to 6 \mathsf {mm }
| Restoring forceinkNat180 bar | ||||||||
| Orderno | Stroke max. | Stroke start | Stroke end | a | b | c39 | d | e |
| 2018.12.04000.049.1 | 49 | 4 | 5,2 | 304 | 109 | 162 | 13 | |
| 2018.12.04000.099.1 | 99 | 4 | 5,2 | 404 | 159 | 89 | 237 | 63 |
| Stroke | 12 | |||
| Orderno 2018.25.04000.035 | +101) 35 | 一 242 | 1 231 | 152 |
| 2018.25.04000.060 | 60 | 292 | 281 | 202 |
| 2018.25.04000.110 | 110 | 392 | 381 | 302 |
| 2018.25.04000.160 | 160 | 492 | 481 | 402 |
| Stroke +101) | |||
| Order no 2018.20.04000.035 | C 207 | 242 | 35 |
| 2018.20.04000.060 | 232 | 292 | 60 |
| 2018.20.04000.110 | 282 | 392 | 110 |
| 2018.20.04000.160 | 332 | 492 | 160 |
| Restoring force inkN*at 20 bar (max.40 bar) | |||||||
| Orderno | Stroke | Imin | a | b | Stroke start | Stroke end | |
| 2018.__.06000.025 | 25 | 211 261 | 262 | 235 | 6,1 | 12.3 | |
| 2018. .06000.050 | 50 | 312 | 285 | 6,1 | 12,3 | ||
| 2018. .06000.100 | 100 | 361 | 412 | 385 | 6,1 | 12,3 | |
| 2018.__.06000.150 | 150 | 461 | 512 | 485 | 6,1 | 12,3 | |
| Orderno | Stroke | Restoring force in kN*at 20 bar (max.40 bar) | Strokeend | |
| 2018.45.06000.025 | 25 | 261 Imin | 6,1 Stroke start | 12.3 |
| 2018.45.06000.050 | 50 | 311 | 6,1 | 12,3 |
| 2018.45.06000.100 | 100 | 411 | 6,1 | 12.3 |
| 2018.45.06000.150 | 150 | 511 | 6,1 | 12,3 |
| *isothermic |
forces should be provided for coping and cutting operations. 2)The cam unit no longer returns completely to its stroke starting position due to the oil expansion which is attributabletothe temperature.Anallowancemustbe made foranincreaseof 3 \mathsf {mm } to 6 \mathsf {mm }
| Restoring force in kNat180 bar | ||||||
| Orderno 2018.11.06000.024 | 24 Stroke max. | e 137 | 一 223 | 191 | 7 Strokestart | Strokeend 10,6 |
| 2018.11.06000.049 | 49 | 162 | 248 | 216 | 7 | 10.6 |
| 2018.11.06000.099 | 99 | 212 | 298 | 266 | 7 | 10,6 |
Cam Unit Compact Cam 60 kN with gas monitoring connection
2018.11.06000.___.1
Installtgether with measuring hoseand controlfiting (gas springand nitrogen connection are valveless).
Duplicate nitrogen gas ports for connecting themeasuring hose.
Useonly one portwhilst keeping the other one closed.
attributable to the temperature.Anallowancemustbe made foranincreaseof 3 \mathsf {mm } to 6 { \mathsf {mm } }
| 一 | Restoring force in kNat180 bar | ||||||
| Orderno 2018.11.06000.024.1 | Strokemax. | e | 223 | 11 191 | 12 103 | Stroke start | Strokeend 10,6 |
| 2018.11.06000.049.1 | 24 49 | 137 162 | 248 | 216 | 153 | 7 7 | 10,6 |
| 2018.11.06000.099.1 | 99 | 212 | 298 | 266 | 228 | 7 | 10,6 |
| Orderno | Stroke+101) | 一 | 12 | |
| 2018.25.06000.035 | 35 | 258 | 247 | 168 |
| 2018.25.06000.060 | 60 | 308 | 296 | 218 |
| 2018.25.06000.110 | 110 | 408 | 396 | 318 |
| 2018.25.06000.160 | 160 | 508 | 496 | 418 |
2018.20.06000.
| Orderno | C | 1 | Stroke+101 |
| 2018.20.06000.035 | 223 | 258 | 35 |
| 2018.20.06000.060 | 248 | 308 | 60 |
| 2018.20.06000.110 | 298 | 408 | 110 |
| 2018.20.06000.160 | 348 | 508 | 160 |
| Order no | Stroke | Imin | a | Restoring force in kN*at 20 bar (max.40 bar) | ||
| b | Stroke start | Stroke end | ||||
| 2018._09000.025 | 25 | 229 | 280 | 254 | 9,1 | 18,1 |
| 2018.__.09000.050 | 50 | 279 | 330 | 304 | 9,1 | 18,1 |
| 2018..09000.100 | 100 | 379 | 430 | 404 | 9,1 | 18,1 |
| 2018._09000.150 | 150 | 479 | 530 | 504 | 9,1 | 18,1 |
| Order no | Stroke | Restoring force in kN*at20 bar (max.40 bar) | Strokeend | |
| 2018.45.09000.025 | 25 | 279 Imin | 9.1 Stroke start | 18,1 |
| 2018.45.09000.050 | 50 | 329 | 9,1 | 18,1 |
| 2018.45.09000.100 | 100 | 429 | 9.1 | 18,1 |
| 2018.45.09000.150 | 150 | 529 | 9,1 | 18,1 |
| *isothermic | ||||
| Strokemax. | e | 1 | Restoring force in kNat150 bar | |||
| Order no 2018.11.09000.024 | 24 | 159 | 268 | 11 236 | 10 Stroke start | Stroke end 14,6 |
| 2018.11.09000.049 | 49 | 184 | 293 | 261 | 10 | 14,4 |
| 2018.11.09000.099 | 99 | 234 | 343 | 311 | 10 | 14,2 |
2018.11.09000.___.1
Installtgetherwithmeasuring hoseand controlfiting (gas springand nitrogen connectionare valveless).
Duplicate nitrogen gas ports for connecting the measuring hose.
Useonly one portwhilst keeping the other oneclosed.
| Orderno | Strokemax. | e | 一 | 」1 | 12 | Restoring forceinkNat150bar | Strokeend |
| 2018.11.09000.024.1 | 24 | 159 | 268 | 236 | 158 | 10 Stroke start | 14,6 |
| 2018.11.09000.049.1 | 49 | 184 | 293 | 261 | 208 | 10 | 14,4 |
| 2018.11.09000.099.1 | 99 | 234 | 343 | 311 | 283 | 10 | 14,2 |
2018.25.09000.
| Orderno | Stroke+101) | 1 | 1 | 12 |
| 2018.25.09000.035 | 35 | 276 | 265 | 186 |
| 2018.25.09000.060 | 60 | 326 | 315 | 236 |
| 2018.25.09000.110 | 110 | 426 | 415 | 336 |
| 2018.25.09000.160 | 160 | 526 | 514 | 436 |
2018.20.09000.
| Orderno | C | 一 | Stroke+101) |
| 2018.20.09000.035 | 241 | 276 | 35 |
| 2018.20.09000.060 | 266 | 326 | 60 |
| 2018.20.09000.110 | 316 | 426 | 110 |
| 2018.20.09000.160 | 366 | 526 | 160 |
2018.__.15000.
| Order no | Strokemax. | 1min | Restoring force in kN*at 20 bar (max.40 bar) | |
| Stroke start | Strokeend | |||
| 2018._.15000.025 | 25 | 250 | 14,5 | 29,0 |
| 2018. .15000.050 | 50 | 300 | 14,5 | 29,0 |
| 2018._ .15000.100 | 100 | 400 | 14,5 | 29.0 |
| 2018.___.15000.150 | 150 | 500 | 14,5 | 29,0 |
| *isothermic | ||||
| Orderno | Stroke | Restoring force in kN*at 20bar (max.40bar) | Strokeend | |
| 2018.45.15000.025 | 25 | lin 310 | Stroke start 14,5 | 29.0 |
| 2018.45.15000.050 | 50 | 360 | 14.5 | 29,0 |
| 2018.45.15000.100 | 100 | 460 | 14,5 | 29,0 |
2)The camunit no longer returns completely to its stroke starting positionduetotheoil expansionwhich isattributable tothe temperature.Anallowancemustbemade foranincreaseof 3 \mathsf {mm } to 6 \mathsf {mm } #
| Stroke max. | 一 | 1 | Restoring force inkNat150bar | |||
| Order no 2018.11.15000.024 | 24 | e 159 | 268 | 236 | Stroke start 15 | 24 Strokeend |
| 2018.11.15000.049 | 49 | 184 | 293 | 261 | 15 | 24 |
| 2018.11.15000.099 | 99 | 234 | 343 | 311 | 15 | 24 |
2018.11.15000.___.1
Installtgetherwith measuring hoseand controlfiting (gas springand nitrogenconnectionare valveless).
Duplicate nitrogen gas ports for connecting themeasuring hose.
Useonly one portwhilst keeping the other one closed.
2)The cam unit no longer returns completely to its stroke starting positiondue totheoil expansionwhich isattributable to the temperature.Anallowancemustbemade foranincreaseof 3 \mathsf {mm } to 6 \mathsf {mm } #
| Order no | Stroke max. | 一 | 11 | Restoring force inkNat150bar | Stroke end | ||
| 2018.11.15000.024.1 | 24 | e 159 | 268 | 236 | 12 109 | 15 Stroke start | 24 |
| 2018.11.15000.049.1 | 49 | 184 | 293 | 261 | 159 | 15 | 24 |
| 2018.11.15000.099.1 | 99 | 234 | 343 | 311 | 234 | 15 | 24 |
2018.25.15000.
| Orderno | Stroke+101) | 1 | 11 | 12 |
| 2018.25.15000.035 | 35 | 307 | 294 | 207 |
| 2018.25.15000.060 | 60 | 357 | 344 | 257 |
| 2018.25.15000.110 | 110 | 457 | 444 | 357 |
| 2018.25.15000.160 | 160 | 557 | 544 | 457 |
2018.20.15000.
| Orderno | C | 1 | Stroke+101) |
| 2018.20.15000.035 | 272 | 307 | 35 |
| 2018.20.15000.060 | 297 | 357 | 60 |
| 2018.20.15000.110 | 347 | 457 | 110 |
Electric hydraulic pump
Note!
The pressure can besetat both valves.
Werecommend setting the low pressurevalve to 25 bar.
Thehigh pressurevalvecanbeset toamaximumof180 bar.
The value to be set depends on the operational requirements.
Technical specifications-hydraulic system
| Oil tank volume | 151 |
| HydraulicoilISOVG32 | DIN51524HVLP(orsimilar) |
| Min.flowat180bar | 1,6I/min. |
| Max.flowat25bar | 8,7/min. |
| Oilpressurewhenextendingandretracting10-20bar | |
| Oilpressureduringoperation | max.180bar |
| Lowandhighpressurevalves | (seenote) |
Technicalspecifications-electricalsystem
| Powersupplyelectrical pump | 3x220-440V-AC 50-60 Hz |
| Controlvoltage&controlvalve | 24V-DC |
| max.oiltemperature | 70+/-5°C |
| Resetswitch-ontemperatureafter overheating | 50° |
| Whenextendingandretracting | duringoperation | |
| Sizeofcam | (Lowpressurephase) | (highpressure phase) |
| 2018.11.01500. | 115mm/s | 21mm/s |
| 2018.11.04000. | 47mm/s | 9mm/s |
| 2018.11.06000. | 29mm/s | 5mm/s |
| 2018.11.09000. | 18mm/s | 3mm/s |
| 2018.11.15000. | 12mm/s | 2mm/s |
Thetable shows theapproximate speedsof onecamunit connectedtoanelectric hydraulic pump.Ifseveral camunitsareconnectedtoanelectric hydraulicpumptoobtainthespeedofeach,divide by the numer of camunits. Example:3×2018.11.01500.024:115mm/s=38mm/s
\*\*The control signal (24VDC) triggers extension of the piston rod and the gas overpressure in the camunit causes retraction.




