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Block cylinders

Hydraulic cylinders with block-type body

 

single acting

with and without spring return

double acting

max. push force: 10 .. 1570 kN
piston diameter: 16 .. 200 mm
rod diameter: 10 .. 125 mm
stroke: 8 .. 200 mm
max. operating pressure: 250 .. 500 bar

Series Data sheet Technical data
B1.5091
B1.5091
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B1.5091 Block cylinders

 

single acting

with and without spring return

max. operating pressure 500 bar

steel housing
piston diameter: 16 .. 100 mm
rod diameter: 10 .. 63 mm
stroke: 8 .. 100 mm
max. push force: 10 .. 392 kN

B1.5094
B1.5094
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B 1.5094 Block cylinders

 

double acting

max. operating pressure 500 bar

steel housing
piston diameter: 16 .. 200 mm
rod diameter: 10 .. 125 mm
stroke: 16 .. 200 mm
max. push force: 10 .. 1570 kN

B1.520
B1.520
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B1.520 Block cylinders

 

for stroke end control

double acting

max. operating pressure 500 bar

steel housing
piston diameter: 16 .. 100 mm
rod diameter: 10 .. 63 mm
stroke: 16 .. 100 mm
max. push force: 10 .. 392 kN

B1.530
B1.530
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B1.530 Block cylinders

 

with adjustable stroke end cushioning

and optional stroke end monitoring

double acting

max. operating pressure 500 bar

steel housing
piston diameter: 25 .. 100 mm
rod diameter: 16 .. 63 mm
stroke: 25 .. 100 mm
max. push force: 24.5 .. 392 kN

B1.5401
B1.5401
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B1.5401 Built-in elements

 

piston and threaded bushing, complete

with sealings for block cylinders

double-acting
max. operating pressure 500 bar

without housing
piston diameter: 25 .. 100 mm
rod diameter: 16 .. 63 mm
stroke: 16 .. 100 mm
max. push force: 24.5 .. 392 kN

B1.542
B1.542
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B1.542 Block cylinders

 

piston rod with external thread

double acting

max. operating pressure 500 bar

steel housing
piston diameter: 25 .. 63 mm
rod diameter: 16 .. 40 mm
stroke: 50 and 63 mm
max. push force: 24.5 .. 155.9 kN

B1.552
B1.552
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B1.552 Block cylinders

 

double acting

with extended piston rod for position monitoring

max. operating pressure 500 bar

steel housing
piston diameter: 25 .. 125 mm
rod diameter: 16 .. 80 mm
stroke: 20 .. 50 mm
max. push force: 20.6 .. 610 kN

B1.553
B1.553
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B1.553 Block cylinders

 

with bronze housing for adjustable magnetic sensors

double acting

max. operating pressure 500 bar

bronze housing
piston diameter: 25 .. 63 mm
rod diameter: 16 .. 40 mm
stroke: 20 .. 100 mm
max. push force: 24.5 .. 155.9 kN

B1.554
B1.554
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B1.554 Block cylinders

 

with aluminium housing for adjustable magnetic sensors

double acting

max. operating pressure 350 bar

Aluminium housing
piston diameter: 25 .. 63 mm
rod diameter: 16 .. 40 mm
stroke: 20 .. 100 mm
max. push force: 17.1 .. 109.2 kN

B1.560
B1.560
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B1.560 Block cylinder, with anti-rotation piston

 

with aluminium housing for adjustable magnetic sensors

double acting

max. operating pressure 350 bar

aluminium housing
piston diameter: 32 .. 50 mm
rod profile P3G: 22 .. 40 mm
stroke: 25 .. 100 mm
max. push force: 28.1 .. 68.7 kN

B1.5601
B1.5601
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B1.5601 Built-in anti-rotation pistons

 

piston and threaded bushing, complete with seals double-acting
max. operating pressure 350 bar

piston diameter: 32 .. 50 mm
rod profile P3G: 22 .. 40 mm
stroke: 25 .. 100 mm
max. push force: 28.1 .. 68.7 kN

B1.570
B1.570
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B1.570 Pull-type cylinders

 

single acting with spring return

max. operating pressure 500 bar

steel housing
piston diameter: 16 .. 100 mm
rod diameter: 10 .. 63 mm
stroke: 8 .. 12 mm
max. pulling force: 6 .. 235 kN

B1.711-2
B1.711-2
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B1.711 Threaded-body cylinders with locking piston

 

single acting with spring return

max. operating pressure 500 bar

Block cylinders
max. clamping force: 5 kN
max. retention force: 10 kN
max. load force: 24.5 kN
piston diameter: 20 mm
stroke: 10 mm

B1.738
B1.738
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B1.738 Block cylinders with guide housing

 

max. operating pressure extending 500 bar for steel block cylinders 350 bar for aluminium block cylinders retracting 350 bar for all versions

steel or aluminium housing
piston diameter: 25 .. 63 mm
plunger diameter: 30 .. 70 mm
stroke: 20 .. 63 mm
max. push force: 17.1 .. 156 kN

RHI S-020
RHI S-020
 
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Block cylinders and mini slides with force/stroke measuring system

 

double acting

max. operating pressure 500 bar

piston Ø 25 - 125 mm
stroke: 0 .. 100 mm
stroke measurement with analogue output 0–10 VDC and 4–20 mA
resolution of stroke measurement 12 bit = 6 µm
force measurement with analogue output 0–10 VDC and 4–20 mA
code class IP 67

General application notes
General characteristics of hydraulic equipment
data sheet A 0.100

 

Application notes for single-acting block cylinders
Venting of the spring area
of clamping and support elements
data sheet A 0.110

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figure 1: fixing at the broad side
 
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figure 2: fixation at the rod side
 
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figure 3: fixation at the bottom side
 
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figure 4: internal thread
 
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figure 5: keyway
 
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figure 6: connection with pipe thread
 
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figure 7: manifold-mounting connection K
 
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figure 8: manifold-mounting connection L
 
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figure 9: manifold-mounting connection S
 
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figure 10: manifold-mounting connnection B
 
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figure 11: stroke limitation by distance bushing
 
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figure 12: stroke limitation by distance bushing
 
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figure 13: stroke end control with inductive proximity switches
 
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figure 14: position monitoring with magnetic sensors
 
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figure 15: block cylinder with piston rod with external thread B1.542





















 
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figure 16: Block cylinders with guide housing B1.738












 
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figure17: block cylinder with force/stroke measuring system at the bottom of the cylinder
 

Application
Double-acting block cylinders can be used universally for all hydraulically-operated linear movements.
Single-acting block cylinders can be used for all hydraulically-operated linear movements that do not require a retraction force or where the piston is retracted by an external force.

Function
Double acting

The double-acting functioning allows a force generation in both axial directions (force to push and to pull). This guarantees a high function safety as well as exactly calculable and repetitive times required for the stroke.

Single acting with spring return
When pressurising the cylinder the piston extends. After pressure relief, the piston is retracted by spring force. The pressure spring must not only overcome the friction forces, but must also supply the hydraulic oil back to the reservoir.

Single acting without spring return

When pressurising the cylinder the piston extends. After pressure relief, the piston must be retracted by an external force. Since no pressure spring is installed, this single-acting block cylinder has the same stroke as the double-acting version with the same length.

Fixing possibilities (figures 1-5)
Block cylinders have cross holes and/or longitudinal holes for mounting. For mounting of the block cylinders internal threads can be provided instead of the through holes, optionally at the piston rod side or the bottom side.
As an alternative to a support, hydraulic block cylinders can be fitted in the housing with a keyway, which transfers the cylinder forces to the baseplate surface via a key.

Technical description:
data sheet B1.5091 (single acting)
data sheet B1.5094 (double acting)

 

 

 

 

 

 

 

Hydraulic connecting possibilities (figures 6-10)

Connection with pipe thread (figure 6)


Manifold-mounting with O-ring sealing
Manifold-mounting connection K- with 2 mounting holes (figure 7)
Manifold-mounting connection L - with 4 mounting holes (figure 8)
Manifold-mounting connection S- with 4 mounting holes (figure 9)
Manifold-mounting connection B- with 4 mounting holes (figure 10)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Intermediate strokes (figure 11)
Stroke limitation by distance bushing: Economical and quickly supplied intermediate strokes
A distance bushing is inserted on the piston rod side in the standard cylinder with the next largest stroke and fastened inside the housing. That means the piston can no longer complete the extending stroke and the stroke is restricted by this internal stop, dependent on the length of the bushing.

 

Stroke end control with high-pressure resistant proximity sensors (figure 12)
For every end position, the cylinder housing is given a hole with interior thread, into which a high-pressure resistant, interactive proximity sensor can be screwed. The sensor checks the piston of the cylinder directly. It is sealed on the outside with an O-ring. By means of the switching distance between the sensor and the piston, the switching point can be adjusted to 5 mm before the end position. Only the end positions of the block cylinder are checked by the high-pressure resistant sensors.

 

 

Position monitoring with inductive proximity switches (figure 13)
For a check with commercially available proximity initiators, block cylinders are equipped with a piston rod which passes through the cylinder base. In addition a housing for checking, in which the sensors are adjustably fitted, is flanged on the cylinder base. The sensors are energised by control cams on the piston rod.
The additional housing makes the total length considerably longer but commercially available sensors with M8 x 1 external threads can be used. Because the sensors can be moved, intermediate positions can also be checked.

Position monitoring with magnetic sensors (figure 14)
A permanent magnet is fixed to the piston, and its magnetic field is detected by a magnetic electronic sensor. With block cylinders, the magnetic sensors are fixed to the outside of the housing in slots running lengthwise.

Advantages of using magnetic sensors are:

  • Compact design / minimum space requirement
  • Switching points adjustable by moving the sensors along the lengthwise slots
  • Possibility of checking several positions, as several sensors can be attached in the two lengthwise slots of the housing, irrespective of the length of the slot or the stroke. In one slot, the minimum distance between the switching points is 6 mm; with two slots it is 3 mm.

Block cylinders with adjustable stroke end cushioning B1.530
The stroke end cushioning throttles the flow rate in the last millimetres of the stroke (e.g. 8 mm) and reduces the piston speed and the energy in the end positions. The stroke end cushioning is adjustable and the cushioning effect can be adapted to the corresponding application. In addition, both end positions can be separately adjusted.

Block cylinders with piston rod with external thread B1.542 (figure 15)
Block cylinders with piston rod with external thread can be equipped with a spherical bearing (accessory). Bearing flanges with rod end bearing are available for fixing at the cylinder bottom. Rod end bearings can be screwed and fixed onto the piston rod.

Block cylinders with aluminium housing B1.554 and B1.560
At maximum operating pressure, block cylinders with aluminium housings are restricted to 350 bar and are not suited to abrupt stresses, which occur, for example, with punching and cutting processes. For such applications, block cylinders with bronze housing B1.553 are suitable.

Block cylinders with bronze housing B1.553
The bronze housings have a high strength and can be used with abrupt stresses, which occur, for example, with punching and cutting processes.

Block cylinders with polygonal piston rod B1.560
Block cylinder with aluminium housing and with a polygon-shaped piston rod, which prevents it from torsion. The installed guide is in the position to compensate torques and side loads.

Block cylinders with guide housing B1.738 (figure 16)
Block cylinder of aluminium or steel with guide housing in front, in which a pin is supported. The pin is positively fitted to the piston rod and transfers the hydraulic force to the point of application. All side loads which occur are transferred only to the pin, i.e. the guide housing. The distance of the block cylinder to the effective point allows application in more difficult applications, e.g. welding fixtures

Built-in elements B1.5401 and B1.5601
Built-in elements are directly integrated in the fixture body. Such created cylinders can be used as push or pull cylinders.
The built-in elements consist of piston and threaded bushing. The piston is inserted into the location hole of the fixture.
Then the built-in bushing is screwed into the fixture body. The bushing is let-in flush to the housing.

Block cylinders with force/stroke measuring system (figure 17)
Double-acting block cylinders of data sheet B1.552 are used.
The stroke measuring system is mounted to the cylinder bottom and operated by the extended piston rod of the cylinder.
The stroke measuring system is a highly-precise electro-magnetic system that indicates the piston position with a resolution of 6 µm.
Force measurement is made indirectly by a pressure transducer, which
exactly measures the operating pressure in the cylinder. The resulting force can be calculated by means of the piston area.
The pressure transducer is installed in a space-saving way at the side of the housing or in the cylinder bottom.

 

 

Application notes for single
acting block cylinders
Venting of the spring area
of clamping and support elements
data sheet A 0.110

 

Application notes for
Magnetic sensors
From the User - For the User 118

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figure 1: design of block cylinders - double acting
 
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figure 2: design of block cylinders - single acting


























 
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figure 3: venting of the spring area of single-acting block cylinders
















 
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figure 4: fixation






















 
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figure 5: block cylinder with magnetic sensors
 

Design of block cylinders (figure 1 - 2)

  • double acting
  • single acting

Cylinder body materials
High alloy steel, bronze alloy and special aluminium alloys.

Piston materials
case-hardening steel, hardened
Exceptions:

  • B1.542: high alloy steel, nitrated
  • B1.590: high alloy steel, chromium-plated

Block cylinders with aluminium or bronze bodies are alternatively also equipped with pistons made of stainless steel.

Sealing materials

  • NBR = nitrile butadiene rubber
    Trade name for example: Perbunan
    Operating temperature: -30 to +100 °C
  • FKM = fluoro rubber
    Trade name for example: VITON®
    Operating temperature: -20 to +200 °C

Mounting position
All block cylinders can be installed in any position.

Max. stroke speed
The maximum piston speed for all series is 0.25 m/s.
Exceptions are the block cylinders B1.542 and the hydraulic block cylinders B1.590. Their piston speed is twice as high with 0.5 m/s.

Fittings
Fittings suitable for the Whitworth G pipe thread correspond to DIN 2353, screwed plug type B according to DIN 3852 sheet 2 (with sealing edge or soft seal).
For block cylinders with aluminium or bronze housing only fittings with soft seal (elastic seals) must be used.
Important! No additional sealing materials, such as Teflon ribbon, must be used!

Venting of the spring area of single-acting block cylinders (figure 3)
If there is a possibility that aggressive cutting lubricants and coolants penetrate through the sintered metal air filter into the cylinder's interior, a vent hose has to be connected and be placed in a protected position.
For further notes and provisions see data sheet A0.110.

Leakage rate
ROEMHELD block cylinders do not leak oil when static. When displacing the piston a sealing with minimum leakage is obtained by the double piston sealing.
For the life of the sealing dry operation has to be avoided, so that a residual lubricating film will be tolerated.
Admissible guide values for 1000 double strokes and hydraulic oil HLP 22 are:

  • up to 32 mm piston diameter: < 0.30 cm³
  • from 40 mm piston diameter: < 0.60 cm³

Admissible side loads
Side loads stress the guides for the piston and piston rod of the cylinder and thereby cause a reduction in working life and leakages leading to the destruction of the cylinder. For this reason, side loads should be avoided - especially with single-acting cylinders.
Under no circumstances must the cylinder side load exceed 3 % of the cylinder force at maximum operating pressure (up to 50 mm stroke). In the case of longer strokes please contact us.

Fixation (figure 4)
In principle, screws of tensile strength 8.8 can be used to secure the block cylinders.
If block cylinders are fastened with screws across the cylinder axis, they must be supported above a specific operating pressure.
Block cylinders: from 160/250 bar
Hydraulic block cylinders: from 100/160 bar
(Use as push cylinder / pull cylinder)
The support only has to be a few millimetres high.

Block cylinders with adjustable stroke end cushioning B1.530
If hydraulic cylinders are operated at high speeds, when the piston hits the stroke end position unimpeded, a high amount of energy is released and must be absorbed by the cylinder housing and the threaded bushing. This can lead to a reduction in the cylinder's working life. This can also result in undesirable effects on the actual function, caused by shaking and noise coming from the knocking.
Reducing the speed helps, of course. If this is not possible, however, it is recommended to use a cylinder with integrated hydraulic stroke end cushioning. In the last few millimetres of the stroke (e.g. 8 mm), this stroke end cushioning forces the hydraulic fluid through a hole or similar. By means of this orifice effect, the flow rate is throttled and the piston speed and the energy in the end positions is thus reduced.
The stroke end cushioning is adjustable and the cushioning effect can be adapted to the corresponding application. In addition, both end positions can be separately adjusted.

Block cylinders with magnetic sensors (figure 5)
A permanent magnet is fixed to the piston, and its magnetic field is detected by a magnetic electronic sensor. With block cylinders, the magnetic sensors are fixed to the outside of the housing in slots running lengthwise.

While using magnetic sensors, you must heed the following:
see also: From the User - For the User 118

Influencing the magnetic field by adjacent, magnetisable components (e.g. steel parts):
In order to guarantee perfect functioning, it is recommended to maintain a distance of at least 25 to 30 mm between magnetic sensor and magnetisable components. The function is indeed possible with a smaller distance but this depends highly on the individual circumstances for fitting. Thus ordinary steel bolts can also normally be used for fastening the cylinder. In borderline cases, screws of non-magnetisable steel (e.g. VA screws) can cause an improvement in the magnetic field.

Influencing the magnetic field with adjacent magnetic sensors
If several block cylinders with magnetic sensors are installed directly adjacent to one another, the magnetic sensors can have a reciprocal influence and malfunctions occur. A magnetisable steel sheet can help, placed between the block cylinders, i.e. magnetic sensors, as a shield.

Demands on voltage supply
See data sheet G2.140

Maximum operating temperature for all required components
solenoid: +100 °C
magnetic sensor: + 100 °C
Connecting cable with right angle plug: +90 °C

Path and switching hysteresis of approx. 3 mm
This has to be considered already when adjusting the magnetic sensors.
For static pistons, the magnetic sensor must always be pushed forward to the piston from the opposite direction.

 

Seal kits
for hydraulic elements

data sheet S0.001

show
figure 1: contact bolts and coupling pins
 
show
figure 2: magnetic sensors for position monitoring
 
show
figure 3: spherical bearings for block cylinders B1.542
 
show
figure 4: inductive proximity sensors
 

Contact bolts and coupling pins (figure 1)
for piston rod with internal thread
data sheet G3.800

 

Magnetic sensors for position monitoring (figure 2)
for block cylinders B 1.553 and B 1.554
data sheet G 2.140

 

 

 

Spherical bearings for block cylinders B1.542 (figure 3)
(Rod end bearings and bearing blocks)
data sheet G3.810

 

Inductive proximity sensors (figure 4)
=> see PDF data sheets of the block cylinders

 

 

 

Venting accessories
for venting of the spring area
of single-acting elements
data sheet A0.110

 
show
figure 1: tools for fabrication of an automotive component
 
show
figure 2: tools for fabrication of connecting elements for prams
 
show
figure 3: tool for fabrication of mobile phone housings
 
show
figure 4: operating core pins
 
show
figure 5: operating a slide in a deep-draw mould
 
show
figure 6: operating core puller plates












 
show
figure 7: injection mould
 

Tools for fabrication of an automotive component (figure 1)
5 block cylinders operate these core-pullers for the required dimensional accuracy of the complex shaping of this elbow tube with two additional tube connections.

 

 

 

 

Tools for fabrication of connecting elements for prams (figure 2)
The core-pullers for injection moulding connecting components made out of plastic materials are inserted and retracted by aluminium block cylinders B1.554 for fabrication in exact position.

 

 

 

Tool for fabrication of mobile phone housings (figure 3)
The exact shaping of the inlet for the later installation of the microphone is made during the injection process by dies, which are operated by aluminium block cylinders with magnetic sensors.

Operating core pins (figure 4 )
In the figure the core cylinder is located in the main core. The position monitoring supplies the required information about the position of the core pins.
The connection of cylinder and core puller should be effected by means of a coupling pin, because core pullers are usually self-guiding.

 

 

Operating a slide in a deep-draw mould ( figure 5 )
If it is impossible to install a block cylinder directly due to force or space restrictions, the block cylinder with spherical bearing might be an alternative.
The figure shows the operation of a slide in a deep-draw mould for a container. The position monitoring supplies the required information about the position of the connecting part.

Operating core puller plates (figure 6 )
The figure shows an item which is made in three versions. The core-pins are driven into the corresponding position
by two independently-controlled core puller plates.
Version A core puller plate 1 actuated
Version B core puller plate 2 actuated
Version C core puller plates 1+2 actuated
The core puller plates drive against fixed stops in the front and back position
and are controlled by proximity switches in both positions. This enables an integration into the control of the mould carrier.
The figure shows version A;
Core puller plate 1 is actuated.
Core puller plate 2 is not actuated.
The building height of the foam mould is limited by the mould carrier.
Due to the small and compact dimensions of the block cylinders the core puller plates could be installed in a space-saving way.

Injection mould (figure 7)
2 round break-throughs at the injection side

Construction possibility:
Before opening of the form the profile pins have to be drawn by means of a cylinder.

Requirements:
Control of core-puller at the injection moulding machine.
Both profile pins must be connected by a bridge in order to draw them with one cylinder. Equip tool with limit switches to control cylinder position "on" and "off".

Selected:
Block cylinders with position monitoring
Ø 25/16 x 20 stroke
Part no. 1543-513
Data sheet B1.554

Cycle (portrayed in simplified terms)

  • Mould closed, injected
  • Profiled core retracts
  • Limit switch gives signal
  • Mould opens
  • Workpiece will be removed from mould
  • Mould closes
  • Limit switch gives signal, hydraulic block cylinder pushes the core into the mould
  • Substance is injected
  • New cycle