Industrial Shock Absorber Designs Self-Compensating ACE Controls self-compensating shock absorbers are highly engineered, fixed, multi-orifice units that decelerate moving weights smoothly regardless of changing conditions, and require no adjustment. These versatile performers offer wide effective weight ranges for handling a wider range of applications and increased velocities. As a moving load impacts the shock absorber the piston travels through the stroke and forces hydraulic fluid through the multi-orifice inner tube. The total orifice area decreases at a rate consistent with the decay of impact velocity, resulting in true linear deceleration. The versatile SC2 Series offers soft contact in combination with self-compensating performance. Soft contact is suggested when a low initial reaction force is recognized at impact. The self-compensating feature is utilized to obtain maximum energy absorption capability. Award Winning MAGNUM® Group Adjustable The standard adjustable ACE shock absorber is based on the multiple-orifice design principle and includes a series of orifices machined along the length of a fixed inner tube. The MAGNUM® Group adjustable shock absorber, shown to the right, has a stationary metering tube, with an inner tube that rotates upon adjustment. These unique models offer dual adjustability by turning the stop collar or the hex socket adjuster at the rear. The adjustable shock absorber offers flexibility in application design and selection procedure. When an effective weight change is required, one simply adjusts the setting. The total orifice area changes, providing true linear deceleration. Adjustable models offer a wide range of effective weight. One model is capable of handling numerous applications. Innovation in Deceleration and Motion Control For over 44 years ACE Controls has provided superior deceleration and motion control products to meet the needs of the automotive, steel, machine tool, lumber, theme park, medical, and other industries. Industrial shock absorber innovations include: the adjustable and self- compensating models, as well as the more recent award winning SC2 Heavyweight Series which elevated shock absorber effective weight capacity and energy absorption capability to new heights. In 1999 ACE introduced the ultimate in shock absorber design…the award winning MAGNUM® Group, offering up to 390% of the effective weight capacity, plus up to 150% of the energy per cycle of standard models. Lifetime Warranty ACE Controls Inc. products are guaranteed to be free of defects in materials and workmanship. ACE will repair or replace any of its products determined to have a defect in materials or workmanship at any time for the life of the product. Award Winning SC2 Heavyweight Series SC2 Heavyweight Design The revolutionary, award-winning SC2 Heavyweight design offers up to 950% of the effective weight capacity and up to 280% of the energy absorption capability of standard models. These durable units combine the piston and inner tube into a single component, the piston tube, which acts as both the pressure creating and pressure controlling device. The Heavyweight Series offers a full effective weight range for a wider range of applications. Index General Information page Shock Absorber Function .....................................................3 General Information ........................................................4-5 Effective Weight .............................................................6 Quality Construction..........................................................7 Self-Compensation...........................................................8 Selection Procedure..........................................................9 Horizontal Sizing Examples ...................................................10 Inclined and Vertical Sizing Examples...........................................11 Rotary Sizing Examples...................................................12-13 Installation Examples.....................................................14-15 Application Examples for Shock Absorbers ...................................16-17 Industrial Shock Absorber Models...........................................18-19 Model Rating Charts .....................................................20-21 Magnum Group Emergency Shock Absorber Ratings...............................23 Industrial Shock Absorbers MC 5 to MC 600 Self-Compensating, Miniature................................24-27 SC2 190 to SC2 925 Self-Compensating, Miniature..............................28-29 SC 25, 75 & 190 Heavyweight Self-Compensating, Miniature .....................30-31 SC2 300 & SC2 650 Heavyweight Self-Compensating, Miniature ...................32-33 SC 25 to SC 650-HC High-Cycle Self-Compensating ...........................34-37 MA 30 to MA 900 Adjustable, Miniature ......................................38-39 AS 3/8x1" Adjustable, Miniature ............................................40-41 Accessories, Miniature Shock Absorber ......................................42-44 Steel Button/Urethane Cap Assembly Chart for All Models ..........................45 Side Load Adapters for Miniature Shock Absorbers.............................46-47 Side Load Adapters for MAGNUM® Group Shock Absorbers.........................47 MAGNUM® Group – MC, MA, ML Series, Models 33 to 64 .......................48-55 Accessories, MAGNUM® Group.............................................56-58 2 Ordering Information, MAGNUM® Group.........................................59 1-1/2" Bore Series Adjustable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-61 CA 2" to 4" Bore, A 2" and 3" Bore Heavy Industrial Shock Absorbers..............62-69 Air / Oil Tanks..............................................................70 Mounting Hints and Operation Details...........................................71 Safety Shock Absorbers Stacker Crane Shock Absorbers SCS-38 to 63 ................................72-75 Industrial Crane Bumper Shock Absorbers CB 63 to 160.........................76-79 Pet & GLASS Industry Shock Absorbers PET Shock Absorbers .......................................................80 Applications ............................................................81-82 SCP 650ML-1-NB-FG PET Shock Dimensions....................................83 SCP650ML-1-880-FG PET Shock Dimensions....................................84 SCP 650ML-1-ERSB-FG PET Shock Dimensions..................................85 SCP 650ML-1-SBUC-FG and 300M-3-B-FG PET Shock Dimensions..................86 SCP 650ML-1-QCM-FG and SCP 190ME-3-439 PET Shock Dimensions...............87 PET Shock Absorber Application Quick Reference..............................88-89 GLASS Shocks.............................................................90 GLASS Shock Construction...................................................91 GLASS Shock Dimensions....................................................92 M64 x 2, GLASS Shocks.....................................................93 M64 x 2, GLASS Shock Dimensions............................................94 Gas Springs, Hydraulic Dampers, Velocity and Feed Controllers Gas Springs AGS 15 to 28................................................95-105 Hydraulic Dampers HB 15 to 40 ..........................................106-110 Hydraulic Dampers HBD 15 to 40.........................................111-115 Mounting Brackets for Hydraulic Dampers ......................................116 VC Precision Hydraulic Feed Controls......................................118-119 MVC Feed Controls ....................................................120-121 DVC Hydraulic Speed/Feed Controls ......................................122-123 Velocity and Feed Controllers, Installation Examples ..............................124 Media, Catalogs and Distributors ACESIZE, CAD Files and Other Products .......................................125 Other Products........................................................126-127 ACE Overview ............................................................128 Distributors...............................................................129 ACE Controls Inc. · 800-521-3320 · (248) 476-0213 · Fax (248) 476-2470 · www.acecontrols.com · email: [email protected] Shock Absorber Function Virtually all manufacturing processes involve movement of some kind. In production machinery this can involve linear transfers, rotary index motions, fast feeds etc. At some point these motions change direction or come to a stop. Any moving object possesses kinetic energy as a result of its motion. When the object changes direction or is brought to rest, the dissipation of this kinetic energy can result in destructive shock forces within the structural and operating parts of the machine. Kinetic energy increases as an exponential function of velocity. The heavier the object, or the faster it travels, the more energy it has. An increase in production rates is only possible by dissipating this kinetic energy smoothly and thereby eliminating destructive deceleration forces. Older methods of energy absorption such as rubber buffers, springs, hydraulic dashpots and cylinder cushions do not provide this required smooth deceleration characteristic – they are non linear and produce high peak forces at some point during their stroke. The optimum solution is achieved by an ACE industrial shock absorber. This utilizes a series of metering orifices spaced throughout its stroke length and ACE Wine Drop Display Property An ACE shock absorber decelerates a free- provides a constant linear deceleration with the lowest possible reaction falling 100 lb (45 kg) weight so effectively 3 force in the shortest stopping time. that the contents of the glass don’t even spill. ACE Controlled Linear Deceleration Stopping with Rubber Bumpers, Springs, Result: Dashpots or Cylinder cushions (cid:115)(cid:0) (cid:44)(cid:79)(cid:83)(cid:83)(cid:0)(cid:79)(cid:70)(cid:0)(cid:48)(cid:82)(cid:79)(cid:68)(cid:85)(cid:67)(cid:84)(cid:73)(cid:79)(cid:78) (cid:115)(cid:0) (cid:45)(cid:65)(cid:67)(cid:72)(cid:73)(cid:78)(cid:69)(cid:0)(cid:36)(cid:65)(cid:77)(cid:65)(cid:71)(cid:69) (cid:115)(cid:0) (cid:41)(cid:78)(cid:67)(cid:82)(cid:69)(cid:65)(cid:83)(cid:69)(cid:68)(cid:0)(cid:45)(cid:65)(cid:73)(cid:78)(cid:84)(cid:69)(cid:78)(cid:65)(cid:78)(cid:67)(cid:69)(cid:0)(cid:35)(cid:79)(cid:83)(cid:84)(cid:83) Raw Material Production (cid:115)(cid:0) (cid:41)(cid:78)(cid:67)(cid:82)(cid:69)(cid:65)(cid:83)(cid:69)(cid:68)(cid:0)(cid:47)(cid:80)(cid:69)(cid:82)(cid:65)(cid:84)(cid:73)(cid:78)(cid:71)(cid:0)(cid:46)(cid:79)(cid:73)(cid:83)(cid:69) (cid:115)(cid:0) (cid:40)(cid:73)(cid:71)(cid:72)(cid:69)(cid:82)(cid:0)(cid:45)(cid:65)(cid:67)(cid:72)(cid:73)(cid:78)(cid:69)(cid:0)(cid:35)(cid:79)(cid:78)(cid:83)(cid:84)(cid:82)(cid:85)(cid:67)(cid:84)(cid:73)(cid:79)(cid:78)(cid:0) Costs Rubber Bumper Finished Product Scrap Stopping with ACE Shock Absorbers Benefits: (cid:115)(cid:0) (cid:41)(cid:78)(cid:67)(cid:82)(cid:69)(cid:65)(cid:83)(cid:69)(cid:68)(cid:0)(cid:48)(cid:82)(cid:79)(cid:68)(cid:85)(cid:67)(cid:84)(cid:73)(cid:79)(cid:78) ACE Shock Absorber Finished Product (cid:115)(cid:0) (cid:41)(cid:78)(cid:67)(cid:82)(cid:69)(cid:65)(cid:83)(cid:69)(cid:68)(cid:0)(cid:47)(cid:80)(cid:69)(cid:82)(cid:65)(cid:84)(cid:73)(cid:78)(cid:71)(cid:0)(cid:44)(cid:73)(cid:70)(cid:69) of the Machine (cid:115)(cid:0) Improved Machine Efficiency Production (cid:115)(cid:0) Reduced Construction Costs of the Machine Raw Material (cid:115)(cid:0) (cid:50)(cid:69)(cid:68)(cid:85)(cid:67)(cid:69)(cid:68)(cid:0)(cid:45)(cid:65)(cid:73)(cid:78)(cid:84)(cid:69)(cid:78)(cid:65)(cid:78)(cid:67)(cid:69)(cid:0)(cid:35)(cid:79)(cid:83)(cid:84)(cid:83) ACE Shock Absorber (cid:115)(cid:0) Reduced Noise Pollution (cid:115)(cid:0) (cid:50)(cid:69)(cid:68)(cid:85)(cid:67)(cid:69)(cid:68)(cid:0)(cid:37)(cid:78)(cid:69)(cid:82)(cid:71)(cid:89)(cid:0)(cid:35)(cid:79)(cid:83)(cid:84)(cid:83) ACE Controls Inc. · 800-521-3320 · (248) 476-0213 · Fax (248) 476-2470 · www.acecontrols.com · email: [email protected] General Information Comparison 1. Cylinder Cushions and Dashpots (High stopping force at start of the stroke). With only one metering orifice the moving load is abruptly slowed down at the start of the stroke. The braking force rises to a very high peak at the start of the stroke (giving high shock loads) and then falls away 1 rapidly. 2. Springs and Rubber Bumpers (High stopping forces at end of stroke). The moving load is slowed down by a constantly rising reaction force up to the point of full compression. These devices store energy rather than dissipate it, Force 2 which causes the load bounce back. lbs (N) 3 3. ACE Industrial Shock Absorbers (Uniform stopping force through the entire stroke). The moving load is smoothly and gently brought to rest by a constant resisting force throughout the entire shock absorber stroke. The load is decelerated with the lowest possible force in the shortest possible time eliminating damaging force peaks and shock damage to machines and equipment. This is a linear deceleration force stroke curve and is the curve provided by ACE industrial shock absorbers. Stopping stroke 4 Energy Capacity Reaction Force Stopping Time (stopping force) ACE Shock Absorber Hydraulic Dashpot ACE Shock Absorber t ACE Q Force Force Shock Absorber v lbs Hydraulic lbs ft/s t (N) Dashpot (N) (m/s) Hydraulic Dashpot Q Stopping Stroke Stopping Stroke Stopping Time Premise: Premise: Premise: Same maximum reaction force. Same energy absorption Same energy absorption. (area under the curve). Result: Result: Result: The ACE shock absorber can The reaction force transmitted The ACE shock absorber absorb considerably more energy by the ACE shock absorber is stops the moving load in a (represented by the area under very much lower. much shorter time. the curve.) Benefit: Benefit: Benefit: By installing an ACE shock By installing the ACE shock By installing an ACE shock absorber production rates can absorber the machine wear and absorber cycle times are reduced be more than doubled without maintenance can be drastically giving much higher production increasing deceleration forces or reduced. rates. reaction forces on the machine. ACE Controls Inc. · 800-521-3320 · (248) 476-0213 · Fax (248) 476-2470 · www.acecontrols.com · email: [email protected] General Information ACE pioneered the use of one piece / closed end bodies and inner pressure chambers in its range of shock abs orbers. This design concept provides an extremely strong construction which can withstand much higher internal pressures and overload forces without mechanical damage. Consider what happens if the shock absorber is accidentally overloaded or in the unlikely event of partial oil loss due to excessive seal wear or damage. Compare the internal design used by ACE with that of some of its competitors: ACE Shock Absorber Other Shock Absorber Snap Ring (Outer body and inner Outer body and Pressure chamber pressure chamber made from tube stock.) with closed rear end (one-piece) ACE builds its shock absorbers with closed end/one piece Some other manufacturers use bodies and inner pressure bodies and inner pressure chambers which greatly reduces chambers made from tube stock. The internal parts are held in the chance of sudden failure or machine damage in the event by a snap ring etc. which then takes all the load and can fail of an overload. suddenly and catastrophically. What happens with an overload or gradual oil loss? What happens with an overload or gradual oil loss? Harder bottoming out force becomes apparent. The snap ring breaks or is extruded due to excessive force. The shock absorber continues to work and can be replaced Machine damage!! Equipment Stops!! then or at the end of the shift. Production Halted!! Emergency Repair!! Corrective Action: Corrective Action: Remove and replace the shock absorber. Refill with fresh oil Remove and replace the shock absorber with 5 or repair. new one (repair not possible). v = 6.56 ft/sec (2 m/s) v = 4.92 ft/sec (1.5 m/s) v = 3.28 ft/sec (1 m/s) v = 1.64 ft/sec (0.5 m/s) v = 0 ft/sec (0 m/s) (cid:179) (cid:179) (cid:179) (cid:179) (cid:179) (cid:179) (cid:179) (cid:179) (cid:179) (cid:179) *4 *3 *2 *1 *0 P = 5801 psi (400 bar) P = 5801 psi (400 bar) P = 5801 psi (400 bar) P = 5801 psi (400 bar) P = 0 psi (0 bar) * As a moving load impacts the shock absorber, the piston travels through stroke and forces hydraulic fluid through the multi- orifice inner tube. The total orifice area decreases at a rate consistent with the decay of impact velocity, resulting in true linear deceleration. F = Force lbs (N) P = Internal pressure psi (bar) s = Stroke in (m) F/P v t = Deceleration time (s) v = Velocity ft/s (m/s) s/t t ACE Controls Inc. · 800-521-3320 · (248) 476-0213 · Fax (248) 476-2470 · www.acecontrols.com · email: [email protected] Effective Weight Figure A Effective weight is an important factor in selecting shock absorbers. A shock absorber “sees” the impact of an Low Effective Weight object in terms of weight and velocity only; it does not ”see” any propelling force. The effective weight can 25 ft/sec (7.62 m/s) be thought of as the weight that the shock absorber “sees” on impact. Effective weight includes the effect of the propelling force on the performance of the shock absorber. 5 lbs (2. 27 kg) Failing to consider the effective weight may result in improper selection and poor performance of the shock absorber. Under extreme conditions, an effective weight that is too low may result in high forces at the start of stroke (high on-set force). However, an effective weight that is too high for the shock absorber may cause high Figure B forces at the end of stroke (high set-down force). Consider the following examples: Low Effective Weight 1.) A 5 lb (2.27 kg) weight travelling at 25 ft/sec (7.62 Example 1: Orifice Area Is m/s) has 583 lbs (66 Nm) of kinetic energy (figure A). Too Small (High On-Set) On this basis alone, a MA 3325 would be selected. Linear However, because there is no propelling force, the Deceleration calculated effective weight is five pounds – which is Force below the effective weight range of the standard MA 3325. This is a high on-set force at the start of the stroke (Figure B). The solution is to use a specially- 6 orificed shock absorber to handle the load. 2.) A weight of 50 lbs (22.68 kg) has an impact velocity of 0.5 ft/sec (0.15 m/s) with a propelling force of Stroke 800 lbs (111N) (Figure C). The total impact energy is 802.5 inch-pounds. Again, a MA 3325 would be selected based just on the energy. The effective weight is calculated to be 16,050 pounds (7,280 Figure C kg). This is well above the range of the standard MA High Effective Weight 3325. If this shock absorber is used, high-set-down 0.5 f/s (0.15 m/s) forces will result (Figure D). In this case, the solution is to use a ML 3325, which is designed to work in low-velocity, high-effective weight applications. 800 lbs 50 lbs (111 N) (22.68 kg) Computer-Aided Simulation By combining application data with a shock absorbers design parameters, ACE engineers can create a picture of how the shock will perform when impacted by the application load. Peak reaction force, peak deceleration Figure D (G’s), time through stroke, and velocity decay are High Effective Weight identified with extreme accuracy. The user benefits by having the guesswork taken out of sizing decisions and Example 2: Orifice Area Is by knowing before installation how his shock problem Too Large (High Set-Down) will be solved. Linear Simulation is also used to maximize the performance Deceleration of ACE adjustable models by predicting the ideal Force adjustment setting for a particular group of conditions. By using simulation software during product development stages, ACE has maximized the performance of its entire line of deceleration devices for over two decades. Stroke ACE Controls Inc. · 800-521-3320 · (248) 476-0213 · Fax (248) 476-2470 · www.acecontrols.com · email: [email protected] Quality Construction ACE Controls has not only established a reputation as the world leader in deceleration technology, but in quality as well. ACE was awarded ISO 9001 quality status in 1994, and attained ISO 9001:2000 status in 2002. The employees of ACE Controls are dedicated to building a quality product, assuring customer satisfaction and delivering on time. As a result of this employee focus, ACE Controls shock absorbers are built to the highest standards. A majority of ACE shock absorber bodies and inner pressure chambers are fully machined from solid alloy steel. A completely closed-end, one-piece pressure chamber is provided without seals or retaining rings. The advantage of this design is that the ACE shock absorber is able to withstand much higher internal pressures or overload without damage, thereby providing a high operational safety margin. Piston Rod high tensile steel hardened and The features listed on this page are corrosion resistant. representative of the rugged, dependable components that are built into each ACE Controls shock absorber. 7 Main Bearing - system lubricated Piston Ring - hardened for long life Pressure chamber made from hardened alloy steel. Machined from solid with closed rear end to withstand internal pressures up to 14,500 psi (1000 bar). Outer Body - heavy-duty, one piece, fully machined from solid steel to ensure total reliability. ACE Controls Inc. · 800-521-3320 · (248) 476-0213 · Fax (248) 476-2470 · www.acecontrols.com · email: [email protected] Self-Compensation Self-Compensating Shock Absorbers Figure A In cases where non-adjustability is beneficial but the features of an adjustable shock absorber are required, self-compensating shocks meet both needs. With a range of effective weight, a self-compensating shock absorber will provide acceptable deceleration under changing energy conditions. The orifice profile, designed by a computer that constantly arranges the size and location of each orifice while inputting Force changing effective weights, neutralizes the effect of changing fluid coefficients, weight, velocity, temperature and fluid compressibility. Figure A A linear decelerator by definition decelerates a moving weight at Stroke a linear or constant rate of deceleration. The adjustable shock Figure B absorber is able to provide linear deceleration when operated within its energy capacity and effective weight range by dialing in the required orifice area. The resulting force-stroke curve (Figure A) shows optimum (lowest) stopping force. Figure B Figure B shows the force-stroke of a self-compensating shock absorber stopping a weight at the low end of its effective weight Force range. Note how the reaction forces are no longer constant but 8 are still acceptable. The curve is skewed slightly higher at the beginning of the stroke and dips lower at the end. Figure C Figure C is a force-stroke curve of the same self-compensating Stroke shock absorber in Figure B but at the high end of its effective weight range. The energy curve is now skewed upward at the Figure C end of stroke and still yields acceptable deceleration. Figure D Figure D is a family of force-stroke curves: a. Adjustable shock absorber properly tuned, or hydro shock perfectly matched. Force b. Self-compensating shock absorber at the low end of its effective weight range. c. Self-compensating shock absorber at the high end of its effective weight range. d. Adjustable closed down, or hydro shock not matched (dashpot effect). Stroke Figure D d b c Force a Stroke ACE Controls Inc. · 800-521-3320 · (248) 476-0213 · Fax (248) 476-2470 · www.acecontrols.com · email: [email protected]