AZ Pneumatica. Rodless cylinders OPL

Rodless cylinders OPL
Technical data

Features

The cylinder barrel of extruded anodized aluminium has a slot along its entire length. To provide rigidity, the bore is eccentric to the outside diameter. A flexible corrosion resistant steel inner band running along the entire length of the bore and passing through the piston provides a near-zero-leakage metal to metal seal. An outer band of the same material acts as a cover over the slot preventing foreign particles to enter into the cylinder. The aluminium piston is fitted with synthetic bearing rings and houses the internal magnet. A physical connection through the slot between the piston and the external mounting plate allows the power transmission outwards. This solid connection permits the acceptance of big external forces and moments, and minimizes frictional losses. Magnetic switches can be mounted on the aluminium profile with mounting brackets.

The cylinder is available in seven sizes: ø16; 25; 32; 40; 50; 63; 80.
Two versions are available: the basic version (part number begins with OPL), suitable for small and medium loads, and the version with recirculating ball bearing guide (part number begins with OPL-KF), suitable for big loads and precision.

1. Vite per assemblaggio testata
Screw for assembling cylinder head

2. Nastro interno di tenuta, in acciaio resistente alla corrosione
Corrosion resistant steel inner sealing band

3. Nastro esterno di tenuta, in acciaio resistente alla corrosione
Corrosion resistant steel outer sealing band

4. Piastra standard per il montaggio del carico esterno
Standard mounting plate for external loads

5. Foro passante per il fissaggio del carico esterno
Passing-through hole to fasten the external loads

6. Fori filettati per il fissaggio del carico esterno
Threaded holes to fasten the external loads

7. Vite di regolazione ammortizzo
Screw for adjustable end cushoning

8. Guarnizione di tenuta del pistone
Piston sealing

9. Anello guida, in materiale a basso attrito
Bearing ring, low friction material

10. Magnete permanente
Magnet

11. Pattino di scorrimento
Slide shoes

12. Pistone
Piston

13. Guarnizione di ammortizzo
Cushion seal

14. Camicia: profilo estruso con cave per il montaggio dei sensori
Cylinder barrel: extruded profile with grooves for magnetic sensors

15. Cono di ammortizzo
Cushion pipe

SIZING OF RODLESS CYLINDERS

The following steps are recommended to select the suitable type and size of cylinder for the required application:

1. Loads, forces and moments
2. Combined loadings
3. End-stroke pneumatic cushoning
4. Allowable unsupported length - placing of mid supports

LOADS, FORCES AND MOMENTS

mod. OPL
sezione

mod. OPL-KF
sezione2

M = F · r
Bending moments are calculated from the centre of the cylinder or guide rail (radius r), and F indicates the force.

Choice of cylinder is decided by:
- permissible loads, forces and moments;
- performance of the pneumatic end cushions. The main factors here are the mass to be cushioned and the piston speed at start of cushioning (unless external cushioning is used, e.g. hydraulic shock absorbers).

The following table gives the maximum values for light, shock-free operation, which must not be exceeded.
Load and moment data are based on speed 0.2 m/s for series OPL, and on the speed indicated in the table for series OPL-KF.

The theoretical values of action forces are the same both for series OPL and OPL-KF.

To achieve a fully controlled movement and good force margins, we recommend to utilize 50% of the theoretical action forces.

model	bore	theoretical action force at 6 bar [N]	real action force at 6 bar [N]	maximum load [N]	max. moment [Nm]
model	bore	F	Fa	L	Ma	Ms	Mv
OPL	16	120	78	120	4	0.3	0.5
	25	295	250	300	15	1	3
	32	483	420	450	30	2	5
	40	754	640	750	60	4	8
	50	1178	1000	1200	115	7	15
	63	1870	1550	1650	200	8	24
	80	3016	2600	2400	360	16	48

model	bore	maximum speed [m/s]	maximum load [N]		max. moment [Nm]
model	bore	v	L1	L2	Ma	Ms	Mv
OPL-KF	16	3	1000	1000	25	12	25
	25	5	3100	3100	90	35	90
	32	5	3100	3100	133	44	133
	40	3	7100	4000	346	119	346
	50	5	7500	4000	480	170	480

STROKE LENGTH

The stroke length of the cylinders type OPL can be chosen up to 5500 mm; for type OPL-KF maximum stroke 3700 mm.
Longer strokes on request.

TOLERANCES

total lenght of cylinder barrel	cylinder bore
total lenght of cylinder barrel	16	25	32	40	50	63	80
0 ... 1000 mm	+1.8 -0	+1.8 -0	+1.8 -0	+1.8 -0	+1.8 -0	+1.8 -0	+1.9 -0
1001 ... 2000 mm	+1.9 -0	+1.9 -0	+1.9 -0	+1.9 -0	+1.9 -0	+1.9 -0	+2 -0
2001 ... 4000 mm	+2.1 -0	+2.1 -0	+2.1 -0	+2.1 -0	+2.1 -0	+2.1 -0	+2.2 -0
4001 ... 6000 mm	+2.3 -0	+2.3 -0	+2.3 -0	+2.3 -0	+2.3 -0	+2.3 -0	+2.4 -0
> 6000 mm	+2.8 -0	+2.8 -0	+2.8 -0	+2.8 -0	+2.8 -0	+2.8 -0	+2.9 -0

COMBINATE LOADINGS

The maximum allowable loads and moments can be found in the tables in this page. Before using the cylinder, also the following inequation must be fulfilled.
The tables show the maximum loads and moments for light, shock-free operation, which must never be exceeded.
The mass of the carriage has to be added to the total moving mass.

CYLINDER WEIGHT

type	bore	weight of cylinder stroke 0	add per 100 mm of stroke	weight of carriage *
OPL	16	0.25 kg	0.1 kg	-
	25	0.74 kg	0.197 kg	-
	32	1.62 kg	0.354 kg	-
	40	2.10 kg	0.415 kg	-
	50	3.74 kg	0.566 kg	-
	63	6.12 kg	0.925 kg	-
	80	12.42 kg	1.262 kg	-
OPL-KF	16	0.558 kg	0.21 kg	0.228 kg
	25	1.522 kg	0.369 kg	0.607 kg
	32	2.673 kg	0.526 kg	0.896 kg
	40	4.167 kg	0.701 kg	1.531 kg
	50	7.328 kg	0.936 kg	2.760 kg

* Weight of carriage must be added to the load weight to calculate forces and moments, and when using the cushoning diagram.

END-STROKE PNEUMATIC CUSHONING

Calculate your expected moving mass (the mass of the carriage has to be added to the total moving mass) and find the maximum permissible speed at start of cushioning.
Alternatively, take your desired speed and expected mass and find the cylinder size required.
Please note that piston speed at start of cushioning is typically ca. 50% higher than the average speed, and this higher speed determines the choice of cylinder.
If the permitted limit values are exceeded, additional shock absorbers should be fitted in the area of the centre of mass.

max. piston speed at cushoning start

cushionable mass

Cushion length

bore	cushion length [mm]
16	11 mm
25	17 mm
32	20 mm
40	27 mm
50	30 mm
63	32 mm
80	39 mm

MID-SECTION SUPPORTS

To avoid excessive bending and oscillation of the cylinder, mid-section supports are required in relation to stroke length and applied load.
The diagrams show the maximum possible lenght (not the stroke!), depending on the load, without mid-section support and between two supports.
Bending up to max. 0.5 mm is permissible between supports. The mid-section supports are clamped onto the cylinder profile and they can also help to support axial forces.
Anyway, for speeds v > 0.5 m/s the free distance should not be more than 1 meter.
For the series OPL-KF two graphics are given: one should be used if the cylinder is positioned according to drawing 1, the other one if the cylinder is positioned according to drawing 2.

supporto intermedio

k = maximum allowable distance between mountings and/or mid-section supports, related to a given load (L).

DIAGRAMS FOR SERIES OPL

grafico

DIAGRAMS FOR SERIES OPL-KF

carriage in up position	1 = OPL-KF16 2 = OPL-KF25 3 = OPL-KF32 4 = OPL-KF40 5 = OPL-KF50
carriage in side position	1 = OPL-KF16 2 = OPL-KF25 3 = OPL-KF32 4 = OPL-KF40 5 = OPL-KF50

Materials

Cylinder profile, piston: anodized aluminium
End caps: aluminium
Seals: NBR
Support rings: plastic material
Slide shoes: plastic material
Sealing bands: corrosion resistant steel
Screws, nuts: galvanized steel
Mountings: galvanized steel and aluminium
External guide rail Guideway: hardened steel

Corrosive environments

Stainless steel screws can be supplied as option (not for version OPL-KF).

Ambient temperature range

Standard version: -10°C ... +80°C

Supply air treatment

Operating pressure: max 8 bar
Medium: 50µ filtered and dried compressed air
The cylinders are grease lubricated, additional oil mist lubrication is normally not required. If oil mist lubrication is present, it must be present all the time and never interrupted.

Maintenance

Lifetime: 6000 km in standard condition and perfect maintenance. After that, the cylinder can be very easily renewed with a service-package which contains all necessary spare parts.

In normal operating environments we recommend to periodically check and, if necessary, re-lubricate the external guide rail of the cylinder (OPL-KF). Sufficient grease must be always present in the carriages; check that a grease film is visible on the running surface of the guide rail.

To prevent contamination such as fluid ingress, avoid direct spraying toward the outer sealing band. The guide way should always be re-lubricated after any cleaning.

Speed related versions

The standard version of the cylinder is designed for piston speeds from 0.2 m/s to 5.0 m/s.

Slow speed option

Specially formulated grease lubrication facilitates slow, smooth and uniform piston travel in the speed range below 0.2 m/s. This slow speed version is available on request.
Minimum speed with special grease 0.005 m/s.

High speed

For speeds exceeding 5.0 m/s please contact our commercial office.

Installation instructions

Use the threaded holes in the end caps to install the cylinder. Check if mid supports are needed. At least one end cap must be secured to prevent axial sliding when mid support is used.
The cylinder can be installed in any position. To prevent contamination such as fluid ingress, the cylinder should be installed with its sealing band facing downwards.

Start up

The products in this data sheet should not be operated until the machine/application in which they are used has passed necessary inspection according to law regulations.
Important: in case of electric arc welding in the area next to the cylinder or on the machine where the cylinder is installed, the cylinder must be insulated and removed. Otherwise the welding causes permanent damage to the cylinder and the warranty expires.

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