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Hydro Track D80 – precision hydraulic cylinder with BTL7 for defence applications

Hydro Track D80 – precision hydraulic cylinder with BTL7 for defence applications

The D80/d40×150 actuator provides positioning accuracy of ±50–100 μm, a force of 80.4 kN (push) / 60.3 kN (pull), and a typical system response time of 50–150 ms. The integrated BTL7 sensor (resolution ≤2 μm, non-linearity ±50 μm) and S7-1200F + HMI KTP700 controller enable smooth motion profiles, ProfiNet/CANopen integration, and mapping to Vetronics/BMS. The solution includes EMC shielding (MIL-STD-461) and is prepared for environmental testing campaigns (MIL-STD-810).

Facts

  • Operational Accuracy: ±50–100 μm (BTL7 ±50 μm + control/mechanical tolerances).

  • Force: 80.4 kN pushing / 60.3 kN pulling.

  • Dynamics: response time of the system (HMI→PLC→hydraulics) 50–150 ms.

  • Integration: S7-1200F + KTP700, ProfiNet (native), CANopen (CM module) → Vetronics/BMS.

  • Typical Operating Speeds: 150–250 mm/s, depending on flow rate of 40–50 l/min (G1/2).

What distinguishes the Hydro Track D80?

The Hydro Track D80 is a compact hydraulic actuator D80/d40 with a 150 mm stroke, designed for the demanding conditions of the battlefield. The integrated BTL7 provides position data at a frequency of up to 1 kHz, enabling closed-loop control (PID), acceleration profiling (S-curve), and oscillation damping. The steel construction with articulated bearings and a sealing set minimises backlash and friction, enhancing repeatability.

Parameters in Practice:

  • ±50–100 μm – actual system accuracy (measurement + control + mechanics).

  • 50–150 ms – typical response time of the system (from command to motion).

  • 150–250 mm/s – achievable speeds for a flow rate of 40–50 l/min

Precise motion control – tactical advantage

Why is this important? Precision and repeatability translate into shorter setup times, better stabilisation, and reduced exposure of the vehicle/crew. At the core of the D80 is the BTL7 (≤2 μm, ±50 μm) with fast 1 ms sampling. The S7-1200F implements PID control and speed/position profiles, while the KTP700 provides an HMI with real-time setpoint input and diagnostics. As a result, the system maintains the desired position, corrects errors, and smoothly adjusts speed without overshooting, even under disturbances (vibrations, load changes).

What does this offer the operator?

  • Micro-corrections of position (set-point trim) while maintaining stability.

  • S-curve profiles for delicate movements (manipulators, EOD) and ramp profiles for rapid adjustments.

  • Mechanical protection (limits, soft limits, anti-backlash logic).

  • Full visualisation: position, speed, cycle times, alarms.

Proprietary CPP PREMA software (TIA Portal) enables customised HMI/PLC functions: mission presets, service modes, startup procedures, and PDM (predictive maintenance) logic.

Integration with Vetronics/BMS and military networks

Architecture: BTL7 → S7-1200F → HMI KTP700 → ProfiNet network (native) or CANopen (CM module). The system can be mapped to Vetronics/BMS (vehicle layer) and onboard networks CAN/MilCAN.

MilCAN (CANbus for military vehicles): an overlay standard on ISO 11898, offering determinism and interoperability in land platforms; used, among others, in tanks and combat vehicles.
Vetronics/BMS: vehicle electronics and battlefield management systems (C4ISR), integrating sensors, stabilisation, communication, and command.

Integration in Practice:

  • CAN: CM CANopen module for S7-1200, mapping PDO/SDO to MilCAN frames.

  • Ethernet: ProfiNet → gateways to vetronics and BMS buses.

  • Diagnostics: publishing position/speed/events to higher-level systems.

Environmental and EMC Resilience — Requirements vs. Current Status

MIL-STD-810 (e.g., Method 514.8 – vibrations): the standard defines environmental scenarios, test selection procedures, and load levels throughout the equipment’s lifecycle. For vehicle-mounted components, key procedures include vibration/shock, transport shock, and humidity tests.

MIL-STD-461 (e.g., RE102/RS103): requirements for radiated emissions and RF field immunity for devices/subsystems. In practice, systems with electronics (PLC/HMI/sensors) require shielding, filtering, and cable routing in accordance with guidelines.

Honest Assessment of Compliance (D80 Status):

  • No formal MIL-STD-810/461 certifications for the complete system in the provided materials; a test campaign in an accredited laboratory and shielded enclosures for electronics are required.

  • Mechanics/actuator – the steel construction and bearings suggest high durability; electronics require additional shielding/filters and military-grade connectors (e.g., MIL-DTL-38999 for signals).

Customisation: Hardware + Software "Tailored to the Mission"

Mechanical Options: stroke, rod end types (fork, joint, compensating), seal types and materials (e.g., steels 1.0503/1.1191), additional position/pressure/temperature sensors, hoses/fittings, and military-grade signal connectors.

Measurement Options: BTL7 in analog/SSI/CANopen variants (selected based on platform architecture and PDM requirements).

Control Options: S7-1200F (Fail-Safe), communication modules (CM CANopen), PID libraries, and function blocks for motion profiling and diagnostics.

Proprietary CPP PREMA Software: HMI/PLC packages in TIA Portal – motion profile presets (e.g., “aiming”, “manipulation”, “transport”), adaptive controller (vibration damping), cycle logger, service alarms, and quick diagnostic dashboards (MTBF/MTTR/response time).

Speed, Force, and Accuracy – Numerical Data

  • Pushing/Pulling Force: 80.4 / 60.3 kN.

  • Stroke: 150 mm; diameters: D=80 mm, d=40 mm.

  • Weight: 22.611 kg; connections: 2×G1/2.

  • Operational Accuracy: ±50–100 μm (BTL7 ±50 μm).

  • System Response Time: 50–150 ms (typical).

  • Typical Speeds: 150–250 mm/s at 40–50 l/min.

Applications

  • MBT/IFV Targeting Systems – precise adjustments and stabilisation, rapid micro-corrections.

  • EOD Robots / Manipulators – smooth S-curve profiles, no overshooting.

  • Artillery and Aviation Mechanisms – mechanical resilience + position diagnostics.

  • Civilian Industry (Dual-Use) – precise positioning and endurance testing.

Extended FAQ

What is the actual accuracy?
Operationally ±50–100 μm (sensor ±50 μm + control/mechanical tolerances).

What is the system response time?
Typically 50–150 ms from command (HMI) to piston rod movement (sensor 1 ms, PLC 1–10 ms + hydraulics).

What speeds can the cylinder achieve?
In practice 150–250 mm/s at a flow of 40–50 l/min (G1/2).

Do you provide smooth speed control?
Yes — PID loop based on BTL7 data (1 kHz) + proportional valves, configuration in TIA Portal.

Is the system ready for Vetronics/BMS?
Yes — ProfiNet (native), CANopen (CM module), mapping option to MilCAN and BMS.

MIL-STD-810/461 status?
Requires a test campaign and electronics shielding; mechanics are designed for harsh conditions.

Do you offer customisation and proprietary software?
Yes — we configure mechanics, sensors, interfaces and proprietary HMI/PLC software in TIA Portal (mission presets, PDM).

What connectors are foreseen?
Industrial + options for military-grade signal connectors MIL-DTL-38999; hydraulics as per platform requirements.

Can additional sensors (CBM) be added?
Yes — pressure, temperature, flow, vibrations; full support in HMI/PLC and trend logging.

Invitation to MSPO 2025 – see the Hydro Track D80 live

We invite you to the 33rd International Defence Industry Exhibition MSPO in Kielce, taking place on 2–5 September 2025. Centrum Produkcyjne Pneumatyki “PREMA” S.A. – Poland’s leading manufacturer of pneumatics and hydraulic power systems, including specialised hydraulic cylinders for the defence sector – will present its latest solutions for the military and industry.

On site, we will showcase the Hydro Track D80 in a demonstration configuration: precision control (PID, S-curve profiles), integration with ProfiNet/CAN (mapping to Vetronics/BMS), as well as our package of proprietary HMI/PLC software (TIA Portal) with mission presets and PDM/CBM modules. We will also discuss customisation (stroke, end fittings, seals, connectors, sensors) tailored to specific platform requirements.

Visit us at stand 1-E17 to:

  • discover our wide portfolio of reliable pneumatic and hydraulic components,
  • see advanced power systems – including cylinders designed to military requirements,
  • learn how our technologies enhance reliability, precision and efficiency of defence systems,
  • take advantage of expert advice, discuss customisation and integration with your Vetronics/BMS architecture.

Bring your requirements and specifications – at our stand we will prepare initial configuration variants (mechanics + sensors + network), go through test scenarios (including MIL-STD-810/461) and propose an implementation schedule.

Arrange a meeting during MSPO: sklep@cpp-prema.pl • +48 41 361 95 24. See you in Kielce!