anor Goting your system in Syne Part2
hydraulics mit
pneumatics
Getting your system in Sync Part 2
Kenneth D. Rosenbecker, Energy Mfg. Co.
Thu, 2008-07-13 (All day)
Arephasing hydraulic cylinder is essentially a standard cylinder with the addition of one important feature — built-
in orifices or passageways that hydraulically resynchronize cylinder motion, should they come out of
synchronization. These orifices can be on the cap end of the eylinder, the rod end, or both. There are several
methods to accomplish this funetion. However itis accomplished, this orifice permits a small amount of hydraulic
fluid to bypass the cylinder piston in the fully retracted or fully extended position. This make-up fluid allows the
cylinders to rephase (synchronize) themselves, if necessary, during operation, Figure 1,
Rephasing cylinders are typically used in one of two operating,
modes: series or parallel.
Series mode — In this mode, the bore and rod diameters of the
cylinders are of a size such that all eylinders extend or retract an
equal distance when fluid flows into the first or last eylinder in
the series. This type of circuit has a wide range of functions on
many different types of machines.
Parallel mode — Here, as shown in Figure 2, the bores and rod
diameters of the two eylinders are the same. Therefore, Cylinder
Awill extend the same amount as Cylinder B retracts when fluid
enters the cap end of Cylinder A. Similarly, Cylinder A will
retract the same amount as the right cylinder extends when fluid enters the cap end of Cylinder B. This type of
ically used for the steering function on a mobile machine.
circuit
Advantages of the rephasing approach
There are several advantages to using rephasing cylinders. They offer
very high dividing/ combining accuracy, typically two to four times that
of valve-type divider/combiners, and equal to or better than external
gear rotary-type divider /eombiners. Because they combine the functions
of the dividing and actuator element into one component, cost is
x = reduced. Other benefits include:
Elimination of the need for a mechanical connection between.
the actuators — the dividing/ combining accuracy of rephasing type
cylinders is typically high enough that it eliminates the need for any type
of external mechanical connection or torque tube in the application. The
machine operator is easily able to resynehronize at any time during
operation by simply fully extending or retracting the cylinders.
Pressure intensification — Because a rephasing cylinder is a positive-
displacement type device, effective power transfer between actuators is possible due to the pressure intensification
ipdydrauicepneumatis.comfprin200TechZona/CylindersAricleFalee2787TechZane-Cylinders 18anos Geng your system in Syne Part 2
effect, just as with the external gear rotary flow dividers. This is true for both series and parallel operation.
No external connection, device, or plumbing to achieve hydraulic resynchronization — The
resynchronization is done internally within the eylinders., helping minimize cost and size.
No constant parasitic power loss — Resynchronizing orifices are placed at the fully extended or fully retracted
positions. Thus, the potential for parasitic power loss exists only at either or both of those positions, and not at any
other stroke positions.
Disadvantages of rephasing cylinders
‘There are a few drawbacks to rephasing cylinders. They can only be used in linear actuator applications. There is a
potential need for protection from the pressure intensification effect. Depending on design and system parameters,
pressure intensification may cause pressures to exceed the working pressure ratings of the cylinders themselves, or
other components within the system. This may require additional components (ic., relief valves, plumbing, etc.) for
pressure protection, adding cost to the system.
“There is also slightly less design flexibility. A rephasing cylinder combines the functions of actuator and
ivider/combiner into one component. Thus, machine designers and manufacturers have no ability to (physically)
place the divider /combiner in a location separate from that of the actuator itself, should that be desirable.
Recent improvements
Rephasing type hydraulic cylinder technology has existed since the late 1960s or earlier. However, recent design
innovations have made it more dependable and reliable. Following are some of the basic design methods that have
‘been used.
Drilled hole design — one of the most basie ways of providing
a re-phasing orifice is by drilling a small hole perpendicular to the
cylinder tube, but parallel to the work ports, Figure 3. This is a
very low-cost method, Reliability can be questionable, however.
‘The bore of a high-quality hydraulic cylinder may have a surface
finish as fine as 0.1 to 0.25 um. Such a smooth finish is required
to achieve effective piston sealing at pressures to 10,000 psigina
standard cylinder. Any time the soft piston seals travel across a
hole intersecting the tube, the possibility of piston seal damage
exists, possible causing eross-piston leakage.
Slotted wall design — this is another method of achieving a rephasing orifice, by milling a small slot into the
inner wall of the cylinder tube, parallel to the axis of the tube, Figure 4. This improves reliability, as the slot is
milled into the tube with a special tool in parallel with the axis of the tube (as opposed to drilling a perpendicular
hole). The radius of the slot creates a natural ramp to ease the piston seal across the slot.
The slotted wall design provides less chance of damage to the
piston seals when they pass across the slot during extension or
retraction. However, milling the slot isa slightly more expensive
operation than drilling a small hole. And even with the slotted
design, the piston seals still pass over a surface with a
smoothness or finish inferior to that of the inside wall of the
cylinder tube itself. This still can cause damage to the piston
seals, although the likeli-hood is much less than that for the
drilled hole design.
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Rephasing valve within cylinder piston — with this design,
small, double-acting valve is used instead of a static orifice,
Figure 5, Here, the piston seals do not need to pass over a hole or
slot to achieve the rephasing function. Consequently, there is no
chanee of piston seal damage. The resull is greater reliability and
longer life. The rephasing valve design shown has been
sucessfully endurance tested in excess of 100,000 extend/
retract cycles. There is also a higher working pressure capability.
The piston seal of an orifice or slot-type rephasing cylinder will
typically extrude or erode if exposed to pressures over 2500 psig.
‘The rephasing valve design cylinders have no such pressure
limitation. Another benefit is that use of better piston seals becomes possible: urethane piston seals can be used
instead of PTFE. Urethane offers superior wear resistance in such applications. Traditionally, PTFE piston seals
have been used in rephasing cylinders with the drilled hole or slotted wall designs because they cross over holes or
slots in the tube with less propensity for damage (as opposed to nitrile, polyester, or urethane). The low friction
offered by the PTFE seals is the characteristic that makes this possible.
Lastly, there isa faster rephasing response. If an orifice or slot type rephasing cylinder isin its rephasing position
and must move a load, there is a brief period where fluid will inadvertently bypass the piston before the seal closes
off the rephasing hole or slot. The rephasing valve has a quicker response, and as such minimizes inadvertent
bypass flow. However, as might be expected, the rephasing valve is the most expensive option of the three main
designs discussed here.
Contact author Ken Rosenbecher at krosenbecker@energumfg.com or visit www.energymfa.com,
Source URL: http://hydrauliespneumaties.com/200/TechZone/Cylinders/Article/False/21797/TechZone-
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