INTEGRATED HYDRAULIC BRAKE ACTUATORS
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- Morgan Wilson
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1 INTEGRATED HYDRAULIC BRAKE
2 INTEGRATED HYDRAULIC BRAKE INTEGRATED HYDRAULIC BRAKE The integrated hydraulic brake is comprised of a pneumatic cylinder that acts as an actuator and an oleo-dynamic circuit that acts as a brake. The dimensions of the pneumatic cylinder (bore 63) comply with ISO The hydraulic circuit is comprised of a brake fluid tank and one or two flow regulation pins. It can mount one or more (slow-fast) SKIP or STOP valves that are normally open (NO) or normally closed (NC), for the piston rod extension and retraction. The basic feature of this device is that the driving force and the braking force are coaxial, so they do not generate undesired bending moments on the piston rod and the external structures connected to it. Due to its conception, this brake is particularly compact and has reduced dimensions compared to BRK external hydraulic brakes. After a certain operating time, the brake fluid tank must be topped up with oil. This needs doing when the oil level reaches the minimum mark on the rod. With the piston rod right out, the minimum level mark must not project less than 8-10 mm from the cap. Always use Comlube DEXRON ATF hydraulic oil or another compatible product. During the first operating cycles, excess oil is expelled through a hole in the tank. 2 Operating pressure bar MPa psi NC valve actuation pressure bar MPa psi Operating temperature range C F Pneumatic circuit fluid Hydraulic circuit fluid Bore mm Thrust force generated at 6 bar N Pull force generated at 6 bar N Maximum load which can be applied from outside while the rod is lock N Version without valves and with closed pins: Thrust Load on the rod Traction Load on the rod Version with STOP NC valves not operated: Thrust Load on the rod Traction Load on the rod Version with STOP NO valves operated at 6 bar: Thrust Load on the rod Traction Load on the rod Version with STOP NO valves operated at 8 bar: Thrust Load on the rod Traction Load on the rod Speeds at 6 bar and 20 C: mm/min with regulation pin with pin and NO STOP valve with pin and NC STOP valve with pin and NO SKIP valve with pin and NC SKIP valve with pin and NO STOP+SKIP valves with pin and NC STOP+SKIP valves without pin nor regulation (fast retraction) Standard strokes Valve combinations Sensor magnet mm NBR-POLYURETHANE 1 to to to to to to to to 156 Lubricated or unlubricated filtered air. DEXRON ATF (Comlube) the list of compatible oils is available on the web site to to to to to to to (Speeds measured on the brake with 500 mm stroke and using 10 mm ø pipes) 50, 100, 150, 200, 250, 300, 350, 400, 450, 500 Other special strokes up to 500 available on request, but the dimensions of the brake are the same of the immediately higher stroke ones, and the front damping has no action. Piston-out, piston-in and dual regulation The following combinations of valves can be mounted on each regulated section: STOP NO, STOP NC, SKIP NO, SKIP NC, DOPPIO STOP NO, DOPPIO STOP NC, DOPPIO SKIP NO, DOPPIO SKIP NC, STOP NO+STOP NC, SKIP NO+SKIP NC, STOP NO+SKIP NO, STOP NC+SKIP NC, STOP NO+SKIP NC, STOP NC+SKIP NO All versions are provided with a magnet
3 COMPONENTS OIL INTEGRATED HYDRAULIC BRAKE a GUIDE HOLD: galvanised steel b O-RING: NBR c PISTON ROD: thickly chromed steel d PISTON ROD GASKET: polyurethane e GUIDE BUSHING: steel strip with bronze and PTFE insert f INSIDE PISTON: brass g GUIDE RING: PTFE h HEAD: anodized aluminium i CUSHIONING GASKET: NBR j JACKET: anodised and calibrated aluminium section k INTERNAL PIPE: brass l INTERMEDIATE PIPE: steel m PISTON: aluminium n PISTON ROD GASKET: polyurethane o MAGNET: plastoferrite p PISTON GASKET: NBR q PISTON ROD GASKET: polyurethane r SECURING/ASSEMBLY SCREW: self-tapping s BUSH: nickel-plated brass t CHECK VALVE u 21 OIL FILLING VALVE u 22 REGULATION UNIT: anodised aluminium u 23 REGULATION PIN u 24 OIL RECOVERY TANK u 25 OIL LEVEL ROD: galvanised steel u 26 NC VALVE u 27 NO VALVE u 28 CUSHIONING PIN 3
4 SKIP-STOP APPLICATION WITH VALVES NO TO TANK FROM CYLINDER FROM CYLINDER TO TANK NC INTEGRATED HYDRAULIC BRAKE OVERALL DIMENSIONS OF THE VARIOUS VERSIONS Stroke B U max STOP Air inlet SKIP In normally-open (NO) valves, flow moves freely from A to D. When port C is supplied, this operates the SKIP valve and the fluid is forced through the bottleneck generated by the adjusting pin. When port B is supplied, this operates the STOP valve and interrupts the flow of fluid. In normally-closed NC valves, flow is normally inhibited. When port B is supplied, the fluid flows through but it is forced through the bottleneck generated by the adjusting pin. When port C is supplied, flow moves freely from A to D. Air inlet STOP SKIP Air inlet Type A D Regulation only valve per side valve per side a Slots for slim sensor (only on the utility ports side) KEY TO CODES W173 W INTEGRATED PISTON ROD EXTENSION PISTON ROD RETRACTION REGULATION BORE STROKE BRAKE CONTROL VALVES CONTROL VALVES Integrated brake 0 Out 1 In 2 Dual 0 Without valves 1 NO Stop 2 NC Stop 3 NO Skip 4 NC Skip 5 NO Stop NO Skip 6 NO Stop NC Skip 7 NC Stop NO Skip 8 NC Stop NC Skip 0 Without valves 1 NO Stop 2 NC Stop 3 NO Skip 4 NC Skip 5 NO Stop NO Skip 6 NO Stop NC Skip 7 NC Stop NO Skip 8 NC Stop NC Skip 0 Ø 63 Specify the desired stroke in 4 digits (e.g for stroke 500) N.B. With at least one extension control valve and one retraction control valve, type W1732 _ is required. 4
5 ACCESSORIES FOOT - MODEL A + = ADD THE STROKE Code Ø Ø AB AH AO AT AU TR UH H 1 H 2 Weight [g] W Note: Individually packed with 2 screws. N.B.: M8x40 UNI 5931 screws are required for fixing the rear head (see kit ) FEMALE HINGE - MODEL B + = ADD THE STROKE Code Ø B D E Ø G H 3 R S Weight [g] W Note: Supplied with 4 screws, 4 washers, 2 snap rings and 1 pin. N.B.: M8x40 UNI 5931 screws are required for fixing the rear head (see kit ) MALE HINGE - MODEL BA + = ADD THE STROKE Code Ø D E F Ø G H H 3 Weight [g] W Note: Supplied with 4 screws, 4 washers. N.B.: M8x40 UNI 5931 screws are required for fixing the rear head (see kit ) ARTICULATED MALE HINGE - MODEL BAS + = ADD THE STROKE Code Ø cil. E F H H 3 M N Weight [g] W Note: Supplied with 4 screws, 4 washers. N.B.: M8x40 UNI 5931 screws are required for fixing the rear head (see kit ) 5
6 CETOP HINGE FOR MODEL B - MODEL GL Code Ø A B C D E F G H I L M N Weight [g] W Note: Supplied with 4 screws, 4 washers. ISO HINGE FOR MODEL B - MODEL GS Code Ø B C D E G J L M N Weight [g] W Note: Supplied with 4 screws, 4 washers. FRONT FLANGE - MODEL C Code Ø A 1 A B S B 1 ØD 4 W Weight [g] W Note: Supplied with 4 screws. REAR FLANGE - MODEL C + = ADD THE STROKE Code Ø A 1 A B S B 1 ØD 4 L Weight [g] W Note: Supplied with 4 screws. N.B.: M8x40 UNI 5931 screws are required for fixing the rear head (see kit ) 6
7 ROD NUT - MODEL S Code Ø F H CH Weight [g] M16x Note: Individually packed. FORK MODEL GK-M Code Ø Ø M C B A L F D N Weight [g] W M16x Note: Individually packed. ROD EYE - MODEL GA-M Code Ø Ø M C B1 B A L F D Ø G CH Ø G1 Weight [g] W M16x Note: Individually packed. SELF ALIGNING ROD COUPLER - MODEL GA-K Code Ø A B C D ØF ØE SW 1 SW 2 SW 3 SW 4 SW 5 Weight [g] W M16x Note: Individually packed. 7
8 KIT OF REAR HEAD SCREWS Code Description Kit of M8x40 UNI 5931 rear head fixing screws Note: 4 items per pack. CYLINDER BRACKET - VALVE SERIES KCV ISO 1 ISO 1 Code Ø A B C D E D E Applicable valves Weight [g] MACH 16 Series 70 1/8-1/4 ISO 1 - ISO KIT FOR FIXING VALVES TO BRACKETS Code Valve KIT Composition Weight [g] MACH 16 2 HEX. screws M3x25 with washer Series 70 1/8-1/4 2 HEX. screws M4x50 with washer ISO 1 Adaptor + ISO1 base side + screws + washers ISO 2 Adaptor + ISO2 base side + screws + washers 350 VALVE ASSEMBLY ON HYDRAULIC BRAKE 8
9 ACCESSORIES: MAGNETIC SENSORS SENSOR SERIES DSM Code W W W Description Sensor REED DSM2-C525 HS Sensor E. HALL PNP DSM3-N225 Sensor E. HALL NPN DSM3-M225 SERIE DSM Type Contact Max AC/DC voltage V Max current at 25 C ma Power with inductive load VA Power with resistive load Watt Switch-on time m sec Switch-off time m sec Switch-on point Gauss Switch-off point Gauss Operating life Contact resistance Cable length m Cable cross section mm 2 Cable material Circuit REED + VARISTOR + LED 2 wires REED + VARISTOR + LED NO 3 to 48 DC; 3 to 220 AC impulses Soft PVC HALL VERSION PNP/NPN 3 wires HALL EFFECT NO PNP/NPN 6 to 24 V DC impulses Soft PVC DC Version NPN AC Version PNP SENSOR BRACKETS DSM Code Description W Bracket D DST 81 9
10 RETRACTABLE SENSOR WITH INSERTION FROM ABOVE Code Description W HALL N.O. sensor, vertical insertion 2.5 m W HALL N.O. sensor, vertical insertion 300 mm M8 W REED N.O. sensor, vertical insertion 2.5 m W REED N.O. sensor, vertical insertion 300 mm M8 W HALL N.O. sensor, vertical insertion 2 m ATEX W * HALL N.O. sensor, vertical insertion HS 2.5 m W * HALL N.O. sensor, vertical insertion HS 300 mm M8 W * REED N.O. sensor, vertical insertion HS 2.5 m W * REED N.O. sensor, vertical insertion HS 300 mm M8 * For use when standard sensors do not detect the magnet, e.g. near metal masses. Type of contact Switch Supply voltage (Ub) Power Voltage variation Voltage drop Input current Output current Switching frequency Short-circuit TECHNICAL protection DATA Over-voltage TECHNICAL suppression DATA Polarity inversion protection EMC LED display Magnetic sensitivity V W V ma ma Hz Repeatability Degree of protection (EN 60529) Vibration and shock resistance Temperature range C Sensor capsule material 2.5 TECHNICAL m/2 m connecting DATA cable Connecting TECHNICAL cable DATA with M8x1 Wire NO. Category ATEX Certifications Reed Hall EFFECT Hall EFFECT N.O. N.O. N.O. - PNP PNP 10 to 30 AC/DC 10 to 30 DC 18 to 30 DC 3 (peak valve = 6) 3 # # 10% of Ub # 10% of Ub - # 2 # # 10 # 10 # 100 # 100 # 70 # 400 # Yes Yes - Yes Yes - Yes Yes EN EN EN Yellow Yellow Yellow 2.8 mt ± 25% 2.8 mt ± 25% mt ± 20% (for HS) 2.1 mt ± 20% (for HS) - # 0.1 mt # 0.1 mt # 0.1 mt (Ub and ta fixed) IP 67 IP 67 IP 68, IP 69K 30 g, 11 ms, 10 to 55 Hz, 1 mm 30 g, 11 ms, 10 to 55 Hz, 1 mm 30 g, 11 ms, 10 to 55 Hz, 1 mm -25 to to to +45 PA66 + PA6I/6T PA66 + PA6I/6T PA PVC; 2 x 0.12 mm 2 PVC; 3 x 0.14 mm 2 PVC; 3 x 0.12 mm 2 Polyurethane; 2 x 0.14 mm 2 Polyurethane; 3 x 0.14 mm Ex II 3G EEx na II T4 X/Ex II 3D T1 35 C IP 67 ATEX WIRING DIAGRAM 10 Dimensions and data shown in this catalogue are subject to variations at any time without prior notice MNWS01029_GB - IM04_04/2012
INTEGRATED HYDRAULIC BRAKE
INTEGRATED HYDRAULIC BRAKE INTEGRATED HYDRAULIC BRAKE The integrated hydraulic brake is comprised of a pneumatic cylinder that acts as an actuator and an oleo-dynamic circuit that acts as a brake. The
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