Hänchen produces lightweight hydraulic cylinders with H-CFRP piston rods and cylinder tubes in small batches. In mobile and stationary lightweight design, these reduce the weight by up to 80 %, and enable corrosion-free or non-magnetic designs.
With this material, we design and produce components for hydraulic cylinders such as cylinder tubes, piston rods, and protection tubes without metal sliding surfaces.
H-CFRP developed by Hänchen is a high load capacity composite. It's refined to form a construction material, made of carbon fiber and other components.
When producing components for cylinders, the carbon fibers are selected and designed as required. The resulting hybrid materials made of metals and carbon fiber reinforced plastics (CFRP) withstand the very high stress to which they are exposed in hydraulic applications. Lightweight hydraulic cylinders made of H-CFRP have several advantages:
Compared with steel, H-CFRP means a mass reduction of up to 80 % for cylinder tubes, and up to 75 % for piston rods. The weight reduction is especially noticeable for long strokes.
Carbon is a non-magnetizable material. This is relevant e.g. for cylinders with a piston rod made of H-CFRP and a magnetostrictive position transducer, resulting in a shorter installation length.
The high corrosion resistance of carbon in combination with non-corroding metals makes H-CFRP a reliable material. The use of epoxy resins for the matrix, and high-quality fiber, prevents chemical attacks caused by strong alkaline or acid substances.
Carbon fibers have a very low negative coefficient of thermal expansion in longitudinal direction. This makes H-CFRP an interesting material for very precise applications.
The tenacity and stiffness of the anisotropic material H-CFRP are considerably higher in the direction of the fiber than in the perpendicular direction. Depending on the fiber direction, there are different elasticity modules, which permit higher lateral forces.
With moved or accelerated components the energy efficiency can be improved due to the reduced weight. Depending on the application, the load capacity can be increased, or the required drive power reduced. In particular, H-CFRP piston rods make it possible to use smaller hydraulic components while maintaining the performance, and realizing a higher dynamic.
The piston rod of an H-CFRP Lightweight hydraulic cylinder is produced in a single piece, made exclusively of carbon, without a metal sliding surface. The piston is firmly embedded. The piston rods are available as single-rod or double-rod, in the Hänchen hydraulic cylinder series 120, 300 and 320. They can be combined with a steel cylinder tube.
The H-CFRP cylinder tube is round-headed without a metallic inner tube. The design of the H-CFRP cylinder tubes of the hydraulic cylinder series 120 and 300 is identical.
The cylinder tubes of series 320 are equipped with an integrated pressure supply and leak oil ports.
Dimensions, hydraulic parameters
As a counter-sliding surface for seals and high hydraulic pressures, the functional hard surface is applied to the piston rod and the cylinder tube during the production process. Cross-hatching is used to refine the sliding surfaces.
Metallic materials are used for force-transmitting elements such as the threads at the ends of piston rods. These are solidly embedded into the H-CFRP piston rod, thus creating a high-strength compound. This enables customary mounting elements for force transmission to be attached, such as spherical rod eyes or rod flanges.
H-CFRP cylinder tubes can be mounted on the cap side or on the head side using a flange. The H-CFRP protection tube can be load-bearing for pivoted mounts attachments, or non-load-bearing.
For hydraulic cylinders, Hänchen offers various steel alloys and lightweight construction materials. A suitable material must be selected depending on the respective application case.
The essential advantages of H-CFRP are the tremendous weight reduction and the high load capacity of these components. This makes it possible to realize energy-efficient drives.