Hydraulics – Reliable Hydraulic Cylinders for Demanding Applications
Hydraulics is a system converting liquid energy into a controlled force and linear displacement. In industrial solutions, the most critical factors are: the nominal parameters of the actuator, the choice of fluid and sealing materials, correct mounting kinematics, and position diagnostics. At CPP PREMA, we design and manufacture hydraulic cylinders in compliance with the environmental and operational requirements of the end user — from agriculture and construction to mining and railways.
Our piston cylinders D25–D160 (groups 70/71) and rodless (nurnik) cylinders D25–D80 (group 77) operate by default at pn = 16 MPa, in temperatures from −30…+80 °C, with piston speeds up to 0.5 m/s; they are compatible with HL/HM/HG oils (10–450 cSt) and water-based media HFA/HFB/HFC. Feature → benefit: the wide operating window ensures predictable starts in subzero conditions and stable cycle times under high daily loads.
You can translate design and procurement requirements directly into components available immediately in our store: Hydraulika siłowa – sklep CPP PREMA. For precise selection, we recommend: Double-acting cylinders D25–D160 and Rodless (nurnik) cylinders D25–D80.
Parameter Range and Environmental Compliance
Versions of group 70/71 include standard and high-temperature configurations, with options for single- and double-rod operation. Feature → benefit: you flexibly tailor the cylinder to the machine’s thermal cycle without compromising sealing durability. Group 70 is certified for operation in explosive atmospheres of methane and/or coal dust; in mining and power applications this shortens the regulatory path and accelerates commissioning.
In series 70 we apply anti-corrosive protection per PN-EN ISO 12944: C5-I, with substrate preparation Sa 2½ and declared durability M (5–15 years). Feature → benefit: extended coating maintenance intervals and lower maintenance cost in highly corrosive environments (salt spray, fertilizers, humidity, dust).
Materials and Construction
The bodies and end caps are made of structural steel; piston rods are produced from structural, stainless, or acid-resistant steel with chrome plating; inductively hardened variants are available on request. → Benefit: high resistance to wear and impact under peak loads and greater stability of guided motion in continuous 24/7 cycles.
System Integration and Sensing
For position diagnostics we recommend inductive sensors NO/PNP 24 VDC (10–30 V), Ie = 200 mA, IP68, with protection against reverse polarity and short circuits, available in high-pressure versions (350–500 bar) and ATEX. We offer full cable sets with M12 connectors (straight/angled) in lengths 5/10 m. Feature → benefit: repeatable signal to PLC under dusty or washing conditions, reduced commissioning and diagnostic time.
For double-rod “B” braking variants, sensor positions X/Y/Z (90°/180°/270°) are defined according to allowable positions for the given diameter and mounting.
Mounting Kinematics and Design Implicationse
Mounting choice dictates edge loads and force paths in the assembly. F3/F4 (round flanges) enable compact, stiff mounting at head or base; P3/P5 (eyes with spherical/rod joints) compensate misalignment and angular motion; S2 (feet) suits table or frame retrofits including double-rod versions; T4 (intermediate pivot/journal) is preferred for oscillating movement. → Benefit: reduced assembly time and lower risk of premature wear when mounting matches machine kinematics.
Selection Procedure – Engineering Methodology
Force and diameter. Use theoretical force tables for pn = 16 MPa (pushing/pulling) in groups 70/71 to narrow diameter to one or two variants. Feature → benefit: fewer design-to-procurement iterations and faster BOM approval.
Stroke and speed. Assume v_max = 0.5 m/s as the baseline; consult for higher speeds considering braking and guiding. Feature → benefit: you avoid cavitation and end-stroke shocks.
Fluid and seals. Choose between HL/HM/HG oils (10–450 cSt) or HFA/HFB/HFC fluids per HSE/ fire safety requirements. Feature → benefit: stable friction and sealing across the temperature window.
Mounting and geometry. Validate mounting dimensions (KK, PJ, ZB, etc.) in 2D/3D models to eliminate collisions before ordering.
Theoretical Forces at pn = 16 MPa (group 70/71)
| Ø cyl. [mm] | Pushing force – grp. 70 [kN] | Pushing force – grp. 71 [kN] | Pulling force – grp. 70 [kN] | Pulling force – grp. 71 [kN] |
|---|---|---|---|---|
| 25 | 7.85 | — | 4.64 | 3.77 |
| 32 | 12.87 | — | 7.84 | 6.80 |
| 40 | 20.11 | — | 12.55 | 14.03 |
| 50 | 31.40 | — | 18.60 | 21.55 |
| 63 | 49.88 | — | 29.77 | 33.60 |
| 80 | 80.40 | — | 49.00 | 55.00 |
| 100 | 125.60 | — | 75.60 | 75.60 |
| 125 | 196.30 | 246.18 | 115.90 | 134.70 |
| 140 | — | 165.80 | — | 165.80 |
| 160 | 321.50 | 219.80 | 196.00 | 219.80 |
Nominal Parameters of CPP PREMA Hydraulic Cylinders
| Group | Nominal pressure | Temperature range | Piston rod speed (max) | Working media (examples) | Corrosion protection |
|---|---|---|---|---|---|
| 70 / 71 (piston type) | 16 MPa | −30…+80 °C | 0.5 m/s | HL/HM/HG oils (10–450 cSt), HFC (≥35% H₂O), HFA/HFB | Series 70: C5-I, durability class M (5–15 years), Sa 2½; Series 71: anti-corrosion paint |
| 77 (plunger type) | 16 MPa | −30…+80 °C | 0.5 m/s | HL/HM/HG oils, HFC, HFA/HFB | Anti-corrosion coating |
Cylinder Mounting – Engineering Summary
| Code | Catalog name | Characteristics | Typical application |
|---|---|---|---|
| F3 | Head round flange | Rigid mounting on the head side. Ensures good coaxial alignment. | Stationary machines, high bed rigidity. |
| F4 | Base round flange | Rigid mounting on the base side. High load capacity. | Supports, presses, vertical systems. |
| P3 | Base eye with spherical bearing | Compensates for angular misalignment. | Articulated motion, lever mechanisms. |
| P5 | Base eye with clevis bearing | Allows a greater tilt range than P3. Absorbs shocks. | Mobile machines, booms, oscillating assemblies. |
| S2 | Foot mounts (side lugs) | Mounting on plate/frame. Also available for double-rod cylinders. | Beds, platforms, systems with limited front/rear space. |
| T4 | Intermediate trunnions (yoke) | Rotation axis centered in the body. For oscillating movement. | Pivoting installations, compact yokes. |
Product Categories and Application Scenarios
In 24/7 cycles with variable axial loads, we prefer piston cylinders 70/71 — material composition of rods and single/double braking (D/G/B) cushions shocks and stabilizes stops. → Benefit: reduced dynamic forces on guideways and extended seal life.
In mechanisms where return is provided by external force, rods, or springs, rodless (group 77) cylinders are suitable — saving space and mass while maintaining pn = 16 MPa. → Benefit: simplified construction and reduced inertia of the working motion.
Best Practices for Installation and Quality Control
Each cylinder is pressure-tested for tightness. Quality control and anti-corrosion coatings are a standard. Feature → benefit: reduced risk of leaks at start-up and stable operation in dusty or humid environments. Design elements (schematics, hydraulics symbols) can be standardized in our Symbols library and force/speed calculations simplified using our Calculator. For custom or retrofitting orders, consult our Production section.
Application Conclusions and Purchase Recommendation
Using correct mounting (F3/F4 for rigid mounts; P3/P5 for angular movement; S2/T4 for tables and pivot) limits edge stresses and removes collisions already at modeling stage—this shortens deployment time and lowers correction costs. The parameters 16 MPa / −30…+80 °C / 0.5 m/s, combined with catalog selection of HL/HM/HG, HFA/HFB/HFC, guarantee predictability across the full service life. Feature → benefit: decision-making based on data, not guesswork — and real time savings for your maintenance team.
How to Read a Hydraulic Cylinder Order Code
- Select the group and diameter. 70/71 (piston) or 77 (plunger) + diameter letter: D/E/F/G/H/J/K/L/T/M (e.g., H = 63 mm).
- Specify the execution. 1 – single-rod; 2 – double-rod (S2); 3/4 – for high-temperature service.
- Choose the mounting. F3, F4, P3, P5, S2, T4 – according to kinematics and geometry.
- Enter the stroke. Four digits, e.g., 0500 for 500 mm.
- Rod end. Z – external thread; W – internal thread; M – mixed.
- Rod material. No letter – structural steel; K – acid-resistant; N – stainless; H – induction-hardened.
- Cushioning (grp. 70). None – no cushioning; D – at base; G – at head; B – both ends.
- Sensor position (if used). X = 90°, Y = 180°, Z = 270°; e.g., …ZKX.
FAQ – Technical Questions & Selection
Which working fluids are standardly allowed?
HL/HM/HG oils (10–450 cSt) and water-based HFA/HFB/HFC. The fluid defines the sealing choice and recommended service intervals.What are the standard operating parameters?
pn = 16 MPa, temperature range –30…+80 °C, piston speed up to 0.5 m/s (for groups 70/71/77). For extreme applications, consider version 3/4.How to choose the mounting method for machine kinematics?
F3/F4 = flanges (rigid mount); P3/P5 = eye joints (misalignment compensation); S2 = foot mounts; T4 = pivot/journal (oscillation). Choose based on kinematics, not convenience.When to use piston vs rodless cylinders?
Piston (70/71) for double-acting systems; rodless (77) when return force is external (mass, spring, external drive).Are EX versions available?
Yes — group 70 has variants rated for methane/pulverized coal zones. Specify ATEX requirements and environment.How to integrate position sensors with PLC?
Use inductive NO/PNP 24 VDC, IP68 sensors (also high-pressure / ATEX). M12 connectors (straight/angled), 5/10 m cables. Sensor positions X/Y/Z selected by diameter/mounting.How to decode the order code?
Read: group → diameter → execution → mounting → stroke → rod termination → rod material → braking (for group 70). Example: 70.H1F.0500ZK.Can I order the cylinder with sensors already installed?
Yes — order with sensor and cabling (e.g. …ZKX for position X). The store allows you to add sensor and cable in the same transaction.Where to order online?
Components and accessories are available at:
– Hydraulics store:
– Double-acting cylinders:
– Rodless cylinders:Which brand tools support selection?
Use: Production page for custom orders, Calculator for force/speed, Hydraulic Symbols for documentation.