English translation of German original TI-P11-EN-27/01 ... by friction. The national and ... • The rod surface is hardened (at least HRC 52), polished ... • Piston rods, hard-chromiu

Locking, actuating and releasing by hydraulic pressure

SITEMA - PowerStroke

Technical Information

TI-P11-EN-27/01/2010

1/5SITEMA GmbH & Co.KG . Im Mittelfeld 10 . D-76135 Karlsruhe . Phone: +49(0)721/98661-0 . Fax: -11 . www.sitema.com

Technical Information TI-P11

SITEMA - PowerStroke Mould Closing Device Type FSK

Contents1 Functional description ................................................ 22 Important installation prerequisites........................... 33 Accessories.................................................................. 44 Overview sizes............................................................. 5• There is a detailed description of the control and use of the

SITEMA - PowerStroke in the"Assembly Instruction MA-P11“.

PurposeThe Mould Closing Device SITEMA - PowerStroke has beendesigned for holding as well as actuating a clamping rod in onedirection (closing direction). A force proportional to the working pressure is exerted to therod by friction.The national and international regulations must be observed.

Application examplesThe Mould Closing Device SITEMA - PowerStroke is typicallyused in machines for:• Blow moulding• Injection die moulding• other applications requiring high forces for short stroke only

Application example with4 SITEMA - PowerStroke Type FSK

Long workingstroke

ShortPowerStroke

English translation of German original




TI-P11-EN-27/01/2010


1 Functional description1.1 Design

Fig. 1: Design of the SITEMA - PowerStroke (clamping released)

The clamping system of the SITEMA - PowerStroke consistsof the clamping jaws (X) Fig. 1 and the clamping sleeve (Y)Fig. 1 which are braced against each other by springs (Z)Fig. 1. The clamping sleeve is supported in the housing (W)Fig. 1 so that it can be moved hydraulically via the pressureports L and K.

1.2 Release the clampingIf the required minimum pressure is applied to the port L (portK pressure-free), then the clamping sleeve (Y) moves until itreaches the stop, thereby opening its clamping system (seeFig. 1).The proximity switch 2 is energised (clamp released).

1.3 Clamping the rod

Fig. 2: Design of the SITEMA - PowerStroke (rod clamped)

If the port L is switched to pressure-free after insertion of therod, then the unit is ready for the closing stroke.The proximity switch 2 is no longer energised.

1.4 Executing the closing stroke

Fig. 3: Design of the SITEMA - PowerStroke (after closing stroke)

Now pressure can be applied to the port K, which generates theclamping force and the rod is pulled in the closing direction.The resulting closing stroke is normally only limited by thecounterforce of the tool.An adjusting nut with a mechanical stop can be provided as aspecial design.The working force of the SITEMA - PowerStroke can easily becontrolled by the variation of the pressure on the port KThe units can be equipped with an additional proximity switch3 " endposition stroke reached".During normal operation, this signal is never active. By this way,the correct function of the unit can be constantly controlled withhelp of this signal.To release the clamping, hydraulic pressure at port K must beswitched of and pressure must be applied to the port L. As aresult, the rod first moves back a little bit (previously-executedclosing stroke) and then the clamping gets released.

2LK

3X Y ZW

direction of force

closing direction

22LK

3

2K 2L

3

closing direction

closing force

executed closing stroke




TI-P11-EN-27/01/2010


2 Important installation prerequi-sites

2.1 Rod requirementsThe function of the SITEMA - PowerStroke is only guaranteedfor proper rod surfaces:Requirements for rod insertion:

• The rod end is fitted with a lead-in chamfer (min. 3x20°,rounded) as a mounting aid.

• The rod surface is hardened (at least HRC 52), polishedand is within the ISO tolerance field f7. In the operatingrange of the SITEMA - PowerStroke it demonstrates aroughness depth of Rz= 1 to 4 µm.

Optimal conditions arise for:• Piston rods, hard-chromium plated (tolerance f7)• Basic material: elastic limit min 580 N/mm²

induction-hardened HRC 56 - 60 / min. 1 ,5 - 3 mm deep• Hard-chromium plating: 800-1000 HV min 25 +/-5µm deep

J Viscous lubricants and greases may affect the opera-tion of the brake.

2.2 Pressure supplyPressure mediaHLP Hydraulic oil on a mineral base according to DIN 51524-2or similar has to be used. Please contact us if you like to useother fluids.

2.3 ControlPort L port for the pressure supply "release"Port L must be pressurized continuously as long as the rod ismoving or the rod is being inserted. By this way the clamp is inopen position.Before the closing stroke should be executed, the pressure forport L must be switched off.

Pressure port V for the pressure supply „acti-vate clamping“Port V has to be pressurized constantly by the control.Furthermore a pressure-relief valve has to be necessarilyadded at this line.

Port K for the pressure supply closing strokePressure corresponding to the desired closing force is appliedto port K after insertion of the rod and after port L is pressure-free. Thus a clamping force corresponding to the workingpressure is realized and the closing stroke is executed.In no situation may pressure be applied to both ports K and Lof the SITEMA - PowerStroke at the same time.

Fig. 4: Principal scheme of hydraulic control

The hydraulic control has to be provided by the customer on thabasis of the diagram above.In this diagram only logical connections are illustrated. It is theresponibilty of the of the manufacturer to ensure thecompliance to all relevant legal regulations and to check allfunctions after the installation.A clamping of the PowerStroke during the fast movement of theprimary drive has to be avoided, as this can lead to highdynamic braking forces. If necessary, precautions have to bemade to avoid unintended pressure losses at release port L.If a particular quick response of the SITEMA - PowerStroke isrequired, the following preconditions must be met:

• Short piping distances• large valve and pipe cross-sections• fast valve response times

NoteFor standard SITEMA - PowerStroke units, the rod may notleave the clamping unit. However, special versions areprincipally available upon request which also allow the rod tobe removed and inserted with each stroke. In this case, the rod may only be inserted in the released state(proximity switch signal 2 active) through a centre ring. Beforethe rod may be clamped (port L port pressure-free) it has to beensured, that the rod is inserted to at least the "minimuminsertion depth"!

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Auto-Bleeders




TI-P11-EN-27/01/2010


2.4 Monitoring by proximity switchesProximity switch 2 "clamping released" indicates, that the rodis not locked by the SITEMA - PowerStroke . So if this signal is active, the rod/tool can be moved by thestandard drive.Proximity switch 3 "stroke limit reached" shows, that the wholepowerstroke was performed by the unit and that the internalstop of the SITEMA - PowerStroke is reached.In this situation, the closing force is no longer fully active. Sothis signal 3 normally indicates a malfunction of the machine-control or of the SITEMA - PowerStroke .

2.5 Operating conditionsThe immediate environment of the SITEMA - PowerStrokemust be dry and clean. A high degree of contamination in thearea of the mould closing device such as foreign bodies,grease, dirt, grinding dust, shavings may require specialprotective measures. Liquids such as release agents,conservation agents and other liquids or chemicals inside thehousing may reduce the holding force. It is particularlyimportant not to have grease on the rod.

• The machine manufacturer must take measures to ensurethat contamination cannot enter the interior of the housing

• In case of doubt contact SITEMA.The allowed ambient temperature is 0 - 60°C

2.6 Required risk assessmentIt must be ensured that the dimensions and arrangement ofSITEMA - Safety Brakes in safety-relevant applications meetthe requirements of the risk evaluation DIN EN ISO 14121-1and also comply with any further standards and regulationsapplying to the intended use. This is the duty of the systemmanufacturer and the user.

2.7 CE markThe SITEMA - PowerStroke is designed as a component forintegration into a machine or system. The seller of the machineor system must provide information on the clamping unit withthe overall documentation and if applicable ensure that themachine or system carries the CE mark.

3 Accessories3.1 Proximity switchesThe included proximity switch holder on port 2 and on port 3 isintended for commercially-available proximity switches(M12x1, flush mountable, nominal switching distance 2 mm).The proximity switch bracket has a depth stop and is factory-set.The proximity switch itself is not included by default, but it canbe ordered from SITEMA. So an adjustment by the customer isnot necessary.




TI-P11-EN-27/01/2010


4 Overview sizes

Abb. 5: Dimensions SITEMA - PowerStroke FSK

Subject to modification without prior notice

Sizes FSK 45 FSK 70 FSK 100 FSK 110 FSK 125 FSK 140 FSK 160 FSK 180 FSK 200Nominal closing force kN 60 110 300 450 625 800 950 1375 1800Technical dataRod diameter[d] mm 45 70 100 110 125 140 160 180 200Outside diameter [D] mm 160 198 268 298 328 371 398 454 525Total length [H] mm 285 334 439 529 570 626 680 765 850Maximum extended length [HE] mm 311 361 466 557 598 658 713 798 883Closing stroke mm 20 20 20 20 20 20 20 20 20Weight ca. kg 36 66 150 220 253 332 470 620 870HydraulicPressure for closing force 1 bar 100 100 150 200 200 200 200 200 200Hydraulic volume K at full stroke 1 cm³ 160 310 550 660 880 1280 1600 2260 3030Min. release pressure 2 bar 80 75 100 150 150 150 150 160 150Hydraulic volume L at full stroke 2 cm³ 70 130 180 200 270 410 460 550 820Clamping system to initialize spring spring spring spring spring spring hydraulic hydraulic hydraulicClamping system initial pressure 3 bar - - - - - 150 160 150Connecting dimensionsHK mm 60,5 77 118,5 116,5 110,5 118 134 134 134HL mm 136,5 149,5 187,5 196 190 211,5 245 245 245H2 mm 197 222,5 279 285 279 295,5 412 414 414H3 mm 190,5 215 269 277 271 286 404 406 406w 20° 20° 20° 20° 20° 15° 20° 20° 20°D1 mm 105 120 150 185 200 215 230 250 275X mm 30 21 30 35 35 38 35 35 35L1 mm 130 160 200 237 264 260 290 340 390n 6x60° 6x60° 6x60° 10x36° 8x45° 8x45° 8x45° 10x36° 10x36°G M10 M12 M16 M16 M20 M24 M24 M24 M30T1 mm 20 25 25 25 30 40 50 50 60

Port: clamping andmould closingsee 1Port: clamping release see 2Port:activate clampingsee 3Proximity switch port: 2Signal „unclamped“Initiator 3Signal „stroke limit rea-ched“

K

2Closing direction

Direction of force

V

L

(Maximum extended length)

)

) Optional equipment

3 )

)

Locking, actuating and releasing by pneumatic pressure



TI-P12-EN-07/2012


Technical Information TI-P12

SITEMA - PowerStrokeMould Closing Device Type FSKP

Contents

1 Functional description ................................................ 22 Important installation prerequisites........................... 33 Accessories.................................................................. 44 Overview sizes............................................................. 5

• There is a detailed description of the control and use of the SITEMA - PowerStroke type FSKP in the„Assembly Instruction MA-P12“.

PurposeThe mould closing device SITEMA - PowerStroke type FSKPis a clamping unit with a a strong integrated short strokecylinder.

For this device, only pneumatic and no hydraulic is necessary.

Application examplesThe SITEMA - PowerStroke shows its strength, if short strokeswith high force (PowerStroke) and long strokes with smallforces (working stroke) are required in the same application,and no hydraulic is available or desired.

The SITEMA - PowerStroke is further not limited to the endposition of the drive only, but can be used within the full strokeof the drive.

The unit can be mounted on a standard cylinder or on aseparate rod.

So the unit can be used for the following applications:

• mould closing• die cutting• stamping • riveting• bending• metal forming• compression moulding• crushing• jointing• fixation

SITEMA - PowerStroke mounted on a

p

p

Long working

Short

stroke

PowerStroke

Application example with

standard pneumatic-cylinder

English translation of German original




TI-P12-EN-07/2012


1 Functional description1.1 Design

Fig. 1: Design of the SITEMA - PowerStroke (clamping released)

The clamping system of the SITEMA - PowerStroke consists ofthe clamping jaws (X) Abb. 1 and the clamping sleeve (Y)Abb. 1 which are braced against each other by springs (Z)Abb. 1. The clamping sleeve is supported in the housing (W)Abb. 1 so that it can be moved hydraulically via the pressureports L and K.

1.2 Release the clampingIf the required minimum pressure is applied to the port L (portK pressure-free), then the clamping sleeve moves counter tothe locking direction until it reaches the stop, thereby openingthe clamping system (see Abb. 1).

The proximity switch 2 is energised (clamp released).

1.3 Clamping the rod

Fig. 2: Design of the SITEMA - PowerStroke (rod clamped)

If the port L is switched to pressure-free after insertion of therod, then the unit is ready for the closing stroke.

The proximity switch 2 is no longer energised.

1.4 Executing the closing stroke

Fig. 3: Design of the SITEMA - PowerStroke (after closing stroke)

Now pressure can be applied to the port K, which generates theclamping force and the rod is moved in the closing direction.

The resulting closing stroke is limited by the counterforce of thetool.

The working force of the SITEMA - PowerStroke can easily becontrolled by the variation of the pressure on the port K

The units can be equipped with an additional proximity switch3 " endposition stroke reached".

During normal operation, this signal is never active. By this way,the correct function of the unit can be constantly controlled withhelp of this signal.

To release the clamping, the pneumatic pressure at port K mustbe switched of and pressure must be applied to the port L. Asa result, the rod first moves back a little bit (previously-executedclosing stroke) and then the clamping gets released.

L

K

23

L

K

23

X

Y

Z

W

clos

ing

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ctio

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dire

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23

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K

23

L

K

23

23

clos

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dir

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d cl

osi

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stro

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TI-P12-EN-07/2012


2 Important installation prerequi-sites

2.1 Rod requirementsThe function of the SITEMA - PowerStroke is only guaranteedfor proper rod surfaces:

Requirements for rod:

• The rod end is fitted with a lead-in chamfer (min. 3x20°,rounded) as a mounting aid.

• The rod surface is hardened (at least HRC 52), polishedand is within the ISO tolerance field f7. In the operatingrange of the SITEMA - PowerStroke it demonstrates aroughness depth of Rz= 1 to 4 µm.

Optimal conditions arise for:

• Piston rods, hard-chromium plated (tolerance f7)• Basic material: elastic limit min 580 N/mm²

induction-hardened HRC 56 - 60 / min. 1 ,5 - 3 mm deep• Hard-chromium plating: 800-1000 HV min 25 +/-5µm deep

J Viscous lubricants and greases may affect the opera-tion of the brake.

2.2 Pressure supplyPressure mediaThe compressed air must be dried and filtered.

2.3 Control

Port L port for the pressure supply "release"Port L must be pressurized continuously as long as the rod ismoving or the rod is being inserted. By this way the clamp is inopen position.

Before the closing stroke should be executed, the pressure forport L must be switched off.

Port K for the pressure supply closing strokePressure corresponding to the desired closing force is appliedto port K after insertion of the rod and after port L is pressure-free. Thus a clamping force corresponding to the workingpressure is realized and the closing stroke is executed.

In no situation may pressure be applied to both ports K and Lof the SITEMA - PowerStroke at the same time.

Fig. 4: Principal scheme of pneumatic control

The pneumatic control has to be provided by the customer ontha basis of the diagram above.

In this diagram only logical connections are illustrated. It is theresponibilty of the of the manufacturer to ensure thecompliance to all relevant legal regulations and to check allfunctions after the installation.

A clamping of the PowerStroke during the fast movement of theprimary drive has to be avoided, as this can lead to highdynamic braking forces. If necessary, precautions have to bemade to avoid unintended pressure losses at release port L.

If a particular quick response of the SITEMA - PowerStroke isrequired, the following preconditions must be met:

• Short piping distances• large valve and pipe cross-sections• fast valve response times• appropriate control

NoteDuring the release process of the SITEMA - PowerStroke, forceon the rod is not allowed. This has to be considered in thecontrol of the machine.

At vertical applications, it may be necessary to induce acounterforce with the drive, in the range of the load of themoved tool (counter balance). So the lowering of the machinepart can be prevented after releasing the clamp.




TI-P12-EN-07/2012


2.4 Monitoring by proximity switchesProximity switch 2 "clamping released" indicates, that the rodis not locked by the SITEMA - PowerStroke.

So if this signal is active, the rod/tool can be moved by thestandard drive.

Proximity switch 3 "stroke limit reached" shows, that the wholepowerstroke was performed by the unit and that the internalstop of the SITEMA - PowerStroke is reached.

In this situation, the closing force is no longer fully active. Sothis signal 3 normally indicates a malfunction of the machine-control or of the SITEMA - PowerStroke.

2.5 Operating conditionsThe immediate environment of the SITEMA - PowerStrokemust be dry and clean. A high degree of contamination in thearea of the mould closing device such as foreign bodies,grease, dirt, grinding dust, shavings may require specialprotective measures. Liquids such as release agents,conservation agents and other liquids or chemicals inside thehousing may reduce the holding force. It is particularlyimportant not to have grease on the rod.

• The machine manufacturer must take measures to ensurethat contamination cannot enter the interior of the housing

• In case of doubt contact SITEMA.The allowed ambient temperature is 0 - 60°C

2.6 Required risk assessmentIt must be ensured that the dimensions and arrangement ofSITEMA - Safety Lock KRGM in safety-relevant applicationsmeet the requirements of the risk evaluation DIN EN ISO12100:2011-03 and also comply with any further standards andregulations applicable for the intended use. All connection,links and fixations have to be dimensioned accordingly. This isthe duty of the system manufacturer and the user.

2.7 CE markThe SITEMA - PowerStroke is designed as a component forintegration into a machine or system. The seller of the machineor system must provide information on the clamping unit withthe overall documentation and if applicable ensure that themachine or system carries the CE mark.

3 Accessories

3.1 Proximity switchesThe included proximity switch holder on port 2 and on port 3 isintended for commercially-available proximity switches(M12x1, flush mountable, nominal switching distance 2 mm).

The proximity switch bracket has a depth stop and is factory-set.

The proximity switch itself is not included by default, but it canbe ordered from SITEMA. So an adjustment by the customer isnot necessary.




TI-P12-EN-07/2012


4 Overview sizes for mounting on separate rod

Fig. 5: Dimensions SITEMA - PowerStrokeType FSKP


Ordering example: FSKP 020 01

für FSKP 20/3-S for mounting on separate rod

TypeIdent number

FSKP16/3-SFSKP 016 01



Nominal pressure 1 bar 6 6 6

Closing force at nominal pressure kN 11,5 19 27,5

Maximum allowable pressure bar 6,5 6,5 6,5

Closing force max. allowable pressure kN 12,5 21 30

Minimum operating pressure bar 5 5 5

Technical data

Rod diameter [d] mm 16 20 25

Outside diameter [D] mm 126 148 177

Total length [H] mm 227 228 254

Maximum extended length [HE] mm 244 245 271

Closing stroke mm 12 12 12

Norm volume at full stroke 1 dm³ 0,38 0,56 0,79

Weight ca. kg 7,5 10 15,5

Connecting dimensions

HK mm 18 18 21

HL mm 160,5 159 171

H2 mm 195,5 196 214,5

H3 mm 191,5 192 210,5

D1 mm 80 95 145

X mm 14 14 26,5

D2 mm 85 100 110

Z mm 3 3,5 3,5

L1 mm 92 110 150

L2 mm 95 115 125

G mm M6 M8 M8

T1 mm 12 15 18

Port: clamping andmould closingsee 1

Port: clamping release minimum 5 bar

Proximity switch port: 2Signal „unclamped“

Proximity switch port: 3Signal „stroke limitreached“

K

2

Closing direction

Direction of force

L


)


) ))

3 )




TI-P12-EN-07/2012


5 Overview sizes for mounting on standard cylinders ISO 15552

Fig. 6: Dimensions SITEMA - PowerStrokeType FSKP


Ordering example: FSKP 020 11für FSKP 20/3-Z for mounting on standard cylinders ISO 15552

TypeIdent number

FSKP16/3-ZFSKP 016 11



Nominal pressure 1 bar 6 6 6

Closing force at nominal pressure kN 11,5 19 27,5

Maximum allowable pressure bar 6,5 6,5 6,5

Closing force max. allowable pressure kN 12,5 21 30

Minimum operating pressure bar 5 5 5

Technical data

Rod diameter [d] mm 16 20 25

Required piston rod extention for standard cylinders ISO 15552 mm 225 225 250

Outside diameter [D] mm 126 148 177

Total length [H] mm 227 228 254

Maximum extended length [HE] mm 244 245 271

Closing stroke mm 12 12 12

Norm volume at full stroke 1 dm³ 0,38 0,56 0,79

Weight ca. kg 7,5 10 15,5

Connecting dimensions

HK mm 18 18 21

HL mm 160,5 159 171

H2 mm 195,5 196 214,5

H3 mm 191,5 192 210,5

D1 mm 80 95 145

X mm 14 19 26,5

D2 mm 85 100 110

Z mm 3 3,5 3,5

L1 mm 92 110 160

L2 mm 95 115 125

G mm M6 M8 M8

T1 mm 12 15 18

TG mm 38 46,5 72

DR mm 6,6 9 11

Port: clamping andmould closingsee 1

Port: clamping release minimum 5 bar

Proximity switch port: 2Signal „unclamped“

Proximity switch port: 3Signal „stroke limitreached“

K

2

Closing direction

Direction of force

L


)


) ))

3 )

Documents

English translation of German original TI-P11-EN-27/01 ... by friction. The national and ... • The rod surface is hardened (at least HRC 52), polished ... • Piston rods, hard-chromiu