EB DESIGN GUIDE CYLINDERS

1 2

INTRODUCTION ...................................................................................................................................................1 TYPICAL GEOMETRY AND NOMENCLATURE..................................................................................................1 2.1 Nomenclature................................................................................................................................................1 2.2 Commonly used cylinder terms .....................................................................................................................2 2.3 Cylinder Ports................................................................................................................................................3 2.3.1 Flanged Ports ....................................................................................................................................3 2.3.2 Threaded ports ..................................................................................................................................3 2.4 Geometry ......................................................................................................................................................4 2.4.1 Bores .................................................................................................................................................4 2.4.2 Lengths..............................................................................................................................................5 CYLINDER FORCE & ASSOCIATED CONSIDERATIONS .................................................................................6 3.1 Governing Equations.....................................................................................................................................6 3.1.1 Resultant Forces ...............................................................................................................................6 3.2 Buckling considerations.................................................................................................................................6 3.3 Internal (support) Stop Tube .........................................................................................................................7 TYPES OF CYLINDER END FITTINGS................................................................................................................8 4.1 Mountings and End fittings ............................................................................................................................8 4.2 Additional Fittings ..........................................................................................................................................9 TYPICAL COSTS FOR CYLINDERS (2004) ......................................................................................................10

INTRODUCTION

Hydraulic cylinders are used extensively at EB to provide equipment with linear motion at a high power density. Hydraulic cylinders are extensively used with mechanical linkages to convert their linear motion into limited rotational motion, eg. A-frame legs and plough skids. The following brief summary sets out to provide the basic considerations of hydraulic cylinders and their application from a mechanical engineering perspective. 2 2.1 TYPICAL GEOMETRY AND NOMENCLATURE Nomenclature

The diagram below shows a typical cylinder with the main components identified as follows: 1) Cylinder Body pressure shell of the cylinder with very smooth (honed internal surface to provide a sliding pressure seal 2) Piston 3) Piston Rod 4) Gland separates the Full Bore and Annulus sides of the cylinder and provides the area against which the hydraulic pressure effectively works. the moving part of the cylinder, note that this one is threaded to take a screw eye/clevis Rod End provides a mechanical bearing for the sliding Piston Rod and also carries the Rod Seals

5) Gland Ring or End Cap holds the Gland in place against the hydraulic pressure within the cylinder, it must resist the full system pressure acting on the Full Bore side of the cylinder.

EBDM - Cylinders Last update: 17/01/2008

Page 1 of 11 Confidential

The Engineering Business Limited

EB DESIGN GUIDE CYLINDERS

6) Piston Seal -

keeps the hydraulic oil on Full Bore and Annulus sides of the Piston separated, usually pressure energised, they provide a sling seal with the cylinder body internal bore retains the hydraulic oil in the annulus side of the cylinder and stops it escaping along the rod. stops oil escaping between the Gland and the Cylinder body

7) Rod Seal 8) Gland Seal -

9) Rod / Piston Seal stops oil passing between the Piston Rod and the Piston 10) Wiper or Scraper Seal scrapes any debris or extraneous material off the rod as the cylinder retracts, and thus protects the Rod Seals in the Gland. 11) Retaining Pin locks the Piston to the Piston Rod, there are several other methods commonly used. 12) Ports Full Bore and Annulus, for connecting the hydraulic supplies to the respective sides of the piston. As illustrated these are threaded ports, and they both usually take the form of bosses welded onto the sides of the Cylinder Body (and not built in as per the Full Bore port in the illustration). also not shown in the illustration, some cylinders have external hard piping to bring the external annulus port to body end of the cylinder, usually close to the full bore port.

13) Transfer tube

2.2

Commonly used cylinder terms the space/volume between the Piston and the end of the Cylinder Body to the right of the Piston in the illustration above. The Full Bore is always greater than the Annulus. the annular space/volume between the Piston and the Gland to the left of the Piston in the illustration above. the mechanical attachment on the end of the Rod, usually a clevis or an eye.

Full Bore

Annulus Rod End

Extend (or Push) oil under pressure is admitted into the Full Bore side of the cylinder, and oil is allowed out of the Annulus side at return or tank (low) pressure; the
EBDM - Cylinders Last update: 17/01/2008 Page 2 of 11 Confidential

The Engineering Business Limited

EB DESIGN GUIDE CYLINDERS

pressure differential causes the piston to extend or move out of the cylinder body. The difference in volume of oil admitted to oil expelled is proportional to the cross sectional area of the Piston Rod. The extend force is always greater than the retract force (for the same pressure) because of this difference in effective areas. Retract (or Pull) oil under pressure is admitted to the Annulus side of the cylinder and oil is expelled from the Full Bore side of the Piston, again at low pressure, the pressure differential causes the piston and Rod to withdraw or retract into the Cylinder Body. The distance between the centrelines of Cylinder Body or rear eye and the Rod Eye when the cylinder rod is fully retracted. The distance between the centrelines of Cylinder Body or rear eye and the Rod Eye when the cylinder rod is fully extended.

Closed Centres Open Centres 2.3

Cylinder Ports

Hydraulic oil enters and leaves a cylinder through Ports, where a hard pipe or hose makes a pressure tight connection to the cylinder body. There are a variety of port styles available; two of which are commonly used by EB; these are 2.3.1 Flanged Ports

These are the EB preferred port type, and are particularly suited to marine and subsea applications. Flanged ports comprise a plain bored hole surrounded by four tapped holes in a flat (machined) face. The mating part carries an O-ring to provide a hydraulic seal and is retained by a pair of split flanges which are fixed into the tapped holes. Flange ports used by EB all comply with an SAE standard, and there are two pressure ranges; SAE 3000 series for pressures up to 3000psi (210 Bar) SAE 6000 series for pressure up to 6000psi (415 Bar)

Specific dimensional detail of these ports can be found in the Systems Tech Ref section. Flanged ports are preferred by EB because the O-ring seals are generally more efficient than bonded seals used with threaded ports especially in subsea applications, the hose ends have some directional (rotational alignment) freedom and they can be made up with small hand tools. They are also usually more easily installed. 2.3.2 Threaded ports

These are occasionally used at EB where it is not possible to obtain cylinders with flanged ports. The preferred port thread is BSP and the seal is effected with a Bonded Seal or Dowty washer between the underside of the hexagonal part of the fitting at the top of the thread and the flat face of the port. The pressure rating of the port is dictated by its size and the corresponding rating of the mating hydraulic fittings. Generally the larger the BSP thread of the fitting the lower the maximum pressure.
EBDM - Cylinders Last update: 17/01/2008 Page 3 of 11 Confidential

The Engineering Business Limited

EB DESIGN GUIDE CYLINDERS

Specific details of BSP threads can be found in the Systems Tech Ref section. 2.4 Geometry

The driving dimensions of a hydraulic cylinder are: Bore and Rod Diameters, which govern the forces that the cylinder can generate to Push or Pull Length of the cylinder when fully retracted or closed (Closed Centres) and fully extended or open (Open centres) from which the physical configuration of the cylinder is derived to give the required range of motion. Bores

2.4.1

The following geometry is taken from the Air Power and Hydraulics (APH) CEPAC range of cylinders. Stroke lengths are generally made to order, although checks should be undertaken to ensure buckling is not an issue if the stroke is exceptionally long compared to the rod diameter. Other makes and sizes are available, however this data should serve for the purposes of preliminary sizing. The pins and bushes commonly used to retain cylinders of the CEPAC range re detailed in the Pins and Lockplates section of the Tech Ref.
Dia (mm) Bore Rod 28.58 31.75 50.80 63.50 76.20 80.00 100.00 125.00 152.40 160.00 200.00 250.00 12.70 18.00 25.40 31.75 44.45 56.00 63.50 70.00 88.90 88.90 110.00 160.00

Series 12 18 21 28 35 38 48 52 63 65 85 100

Standard diameters of rods and bores are driven by the availability of standard sizes of the seals produced for cylinders. It is worth noting that much of the standard ranges of hydraulic cylinders have an imperial heritage. It is possible, and occasionally necessary to fit an oversize rod in a cylinder; as far as the CEPAC series is concerned the next series up rod can generally be fitted, ie. it is possible to have an 89 mm diameter rod in a 52 Series CEPAC cylinder. This is usually as a result of buckling considerations or the need for a reduced pull force.

EBDM - Cylinders Last update: 17/01/2008

Page 4 of 11 Confidential

The Engineering Business Limited

EB DESIGN GUIDE CYLINDERS

2.4.2

Lengths

The salient parameters are: Closed Centres Open Centres the distance though which the rod extends, usually measured between the annular face of the piston and the back of the Gland. the cumulative length of the cylinder that is fixed and not part of the stroke.

Stroke Dead Length -

These are illustrated in the following diagram, and with the listed relationships, most cylinder operating geometrys can be laid out and clevis positions determined.

The following relationships are useful: Closed Centres = Dead Length [DL1 +DL2] + Stroke Open Centres Open Centres = Closed Centres + Stroke = Dead Length + 2 x Stroke

Dead Length always has a fixed minimum value, but can be increased, and Stroke can be varied to suit the application (when new cylinders are being considered). Stroke (of an existing cylinder) can be reduced by fitting a stop tube in the annulus side of the cylinder. Closed centres (of an existing cylinder) may be increased, at the expense of stroke by fitting a stop tube in the full bore side of the cylinder.

EBDM - Cylinders Last update: 17/01/2008

Page 5 of 11 Confidential

The Engineering Business Limited

EB DESIGN GUIDE CYLINDERS

CYLINDER FORCE & ASSOCIATED CONSIDERATIONS

The force that a cylinder can produce depends on the bore and rod diameters (areas) and pressure of the working fluid. 3.1 Governing Equations

Push Force (kN) = Full Bore Area (mm2) x Pressure (Bar) x 10-4 Pull Force (kN) = Annulus Area (mm2) x Pressure (Bar) x 10-4 Annulus area = Bore Area (mm2) Rod Cross Sectional Area (mm2) 3.1.1 Resultant Forces

The following tables show the maximum available push and pull force for a range of cylinder sizes and cylinder pressures.
Max Pressure [Bar] Series 12 18 21 28 35 38 48 52 63 65 85 100 100 Push Pull [kN] 6.4 7.9 20.3 31.7 45.6 50.2 78.5 122.7 182.3 201.0 314.0 490.6 [kN] 5.2 5.4 15.2 23.7 30.1 25.6 46.9 84.2 120.3 138.9 219.0 289.7 150 Push Pull [kN] 9.6 11.9 30.4 47.5 68.4 75.4 117.8 184.0 273.5 301.4 471.0 735.9 [kN] 7.7 8.1 22.8 35.6 45.1 38.4 70.3 126.3 180.4 208.4 328.5 434.5 200 Push Pull [kN] 12.8 15.8 40.5 63.3 91.2 100.5 157.0 245.3 364.6 401.9 628.0 981.3 [kN] 10.3 10.7 30.4 47.5 60.1 51.2 93.7 168.4 240.6 277.8 438.0 579.3 225 Push Pull [kN] 14.4 17.8 45.6 71.2 102.6 113.0 176.6 276.0 410.2 452.2 706.5 1103.9 [kN] 11.6 12.1 34.2 53.4 67.7 57.7 105.4 189.4 270.6 312.6 492.8 651.8 250 Push Pull [kN] 16.0 19.8 50.7 79.1 114.0 125.6 196.3 306.6 455.8 502.4 785.0 1226.6 [kN] 12.9 13.4 38.0 59.4 75.2 64.1 117.1 210.5 300.7 347.3 547.5 724.2 350 Push [kN] 22.4 27.7 70.9 110.8 159.5 175.8 274.8 429.3 638.1 703.4 1099.0 1717.2 Pull [kN] 18.0 18.8 53.2 83.1 105.3 89.7 164.0 294.7 421.0 486.2 766.6 1013.8

It is the responsibility of the engineer specifying the cylinders to ensure that appropriate consideration is given to the relationship between the Stroke and the maximum Push Force against collapse by buckling. This becomes increasingly important with longer strokes. In some cases hydraulic cylinders have the maximum full bore pressure reduced from the maximum system pressure to reduce the buckling risk. 3.2 Buckling considerations

Cylinders with longer rods have a tendency to buckle under compressive loads. Most cylinder manufacturers publish charts for guidance on buckling limits, the basis of these assessments is a modified Euler buckling calculation, taking account of the end or mounting configuration to give a notional Buckling Length (Lb). The following diagram is typical and is produced by APH, and illustrates the relationship between Effective length (E) and the Buckling Length (Lb). Lb is used for the buckling calculation.

EBDM - Cylinders Last update: 17/01/2008

Page 6 of 11 Confidential

The Engineering Business Limited

EB DESIGN GUIDE CYLINDERS

In most cases EB cylinders are pinned at both ends an the case where Lb = E applies, occasionally with long cylinders such as those found in the C147 Extending Roller Box are front flange mounted to reduce the effective buckling length (Lb = 0.7E).

The Euler (buckling) load, Pe, is given by the equation

Pe =

2 EI
Lb 2

The difficulties arise when calculating the I value, as a result of the transmission of the moment from cylinder body to rod in the area of the gland. For an initial scoping assessment considering the cylinder as a tube with the proportions of the cylinder body gives a buckling load in excess of the actual value. Similarly considering the cylinder as all rod under estimates the actual value; the result lies between these. It is usual for safety factors in the region of 3 to 5 to be applied to the Euler Buckling load against the applied load, P. Note that in some cases the safety factors are built into the applied loads by way of duty and dynamic factors. Some of the 3rd party certifying bodies publish specific requirements for the way in which buckling loads should be calculated for hydraulic cylinders; one such example by DNV may be found at http://exchange.dnv.com/Publishing/TAP/5-778-93.pdf . 3.3 Internal (support) Stop Tube

Long stroke cylinders, eg A-Frame cylinders, are sometimes fitted with an internal stop tube between the piston and gland assembly. This increases the bearing spread and thereby reduces the bearing load, especially at full stroke. APH publish the following guidelines for Internal Stop tubes If Lb is less than 1 metre, stop tubes are not generally required If Lb is greater than 1m, then 10mm [REVISED 17/01/2008] of Stop Tube is sometimes recommended for every 250mm beyond 1m.

Note that the Stop Tube increases the Closed Centres of a cylinder for the same stroke. Other cylinder manufacturers alleviate the need for stop tubes by utilizing slightly longer glands and piston bearings.

EBDM - Cylinders Last update: 17/01/2008

Page 7 of 11 Confidential

The Engineering Business Limited

EB DESIGN GUIDE CYLINDERS

Note also that the above are GUIDELINES and are not a substitute for proper consideration of specific cases. 4 TYPES OF CYLINDER END FITTINGS

The following section illustrates some of the common mounting arrangements for hydraulic cylinders. Those found at EB are predominantly fitted with Swivel Eyes at both ends, these help to accommodate the clearances used in EB fabrications which are predominantly pinned together. See the linkages in the C194 equipment supplied to Allseas. Less commonly used are Front Flange and Trunnion mounts, usually for mitigation of buckling issues and sometimes because of geometric or packaging constraints. 4.1 Mountings and End fittings

Swivel Eye Mounting

Rear Eye Mounting

Pad Eye Mounting

Trunnion Mounting

Front Flange Mounting

Foot Mounting

EBDM - Cylinders Last update: 17/01/2008

Page 8 of 11 Confidential

The Engineering Business Limited

EB DESIGN GUIDE CYLINDERS

Rear Flange Mounting

4.2

Additional Fittings

It is often useful or necessary to have remote indication of the position of cylinders, ie a measure of their extension or retraction. This is achieved using: External transducer; typically of the encoder draw wire type part no. as used on Subsea 7 Compensators C186 & C208 (at client request) and also on some early A-frames. Internal transducers; linear displacement types housed within the body of the cylinder. Application notes

4.2.1

The preference at EB is for internal transducers, particularly for subsea or offshore applications; the principal reason is that the transducers are robustly protected against mechanical damage within the cylinder. Less desirable facets are the increased cost of the long drilling down the rod to house the transducer, increased dead length of the cylinder, and the fact that the cylinder must be removed and stripped in the event of a fault developing. External transducers are generally cheaper to implement and easier to service/replace, but are exceedingly vulnerable to mechanical and environmental damage. These are only usually utilised to satisfy client requirements. 4.2.2 Electronic rod positioning indicators

The are generally 4 wire 4-20mA devices and require calibration within the cylinder stroke.

Internal transducers used are from one of two manufacturers, both utilise a, annular permanent magnet travelling with the piston over the fixed transducer stem :-

EBDM - Cylinders Last update: 17/01/2008

Page 9 of 11 Confidential

The Engineering Business Limited

EB DESIGN GUIDE CYLINDERS

Balluf these are the Rolls Royce of in-cylinder transducers and give high precision outputs, resolution is of order 1/10ths of a mm. They operate on the Tempasonic principle, where the relative position of the magnet along the transducer stem is measured by sensing the variation in the magnetic field around the rod along its length. These transducers are used when high integrity and accuracy are required, typically for actuation on subsea vehicles. The incorporation of Balluf transducers into a cylinder increases its Dead Length by approximately 125mm for and APH cylinder; check with the cylinder manufacturer for specific dead length increase.

Rota these are lower cost and operate with a series of reed switches inside the transducer stem. The resolution of the earlier/standard Rota transducers is 3mm, though more recent variants have reduced this resolution to the order of 1mm. Options are available with switches just at the ends of, or at discrete points within the stroke. The Rota transducers are generally cheaper than the Balluf equivalent. They also have a slightly shorter lead time. Again the incorporation of a Rota In-cylinder transducer increases the Dead Length of the cylinder. There are now at least two models of transducer, so check on each case with cylinder manufacturer.

4.2.3

Electrical connectors for in-cylinder transducers

The electrical connector fitted to cylinders with internal transducers is specified, and often free issued, by EB. For subsea and some vessel deck equipment 2 pin 4 pole Electromek (4 6.5 MBORA pattern) subsea connector supplied by Groove Associates, there is an EB standard electrical connection scheme for these connectors, details can be found on electrical circuit diagrams A base EB100 is usually free-issued to the cylinder manufacturer along with the connector. The connection of the mating harness onto the cylinder is usually protected by a pair of low parallel plates located either side of the connector. For less arduous applications a more conventional screw in 4pin (military) type of connector is used. These are generally less robust and are at increased risk of mechanical damage.

HOLD material to be added hydraulic considerations load holding counterbalance valves and their respective locations 5 TYPICAL COSTS FOR CYLINDERS (2004)

The graph below gives an indication of the relative costs for cylinders on a bore and stroke basis. The vertical lines give an approximate range of prices depending on stroke. Additional factors that affect price that should be taken into account are: 1) Rod material / coating: Stainless steel, chrome plated carbon steel or ceramax

EBDM - Cylinders Last update: 17/01/2008

Page 10 of 11 Confidential

The Engineering Business Limited

EB DESIGN GUIDE CYLINDERS

2) Quality of supplier: 3) Delivery: 4) Certification requirements:

9000

Bosch Rexroth / APH / WFE etc Fast track delivery vs OTS (off the shelf) DNV/ Lloyds

8000

7000

6000

Price ()

5000

4000

3000

2000

1000

0 75 100 125 150 175 Bore (mm) 200 225 250 275

EBDM - Cylinders Last update: 17/01/2008

Page 11 of 11 Confidential

The Engineering Business Limited