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Industrial Presses

Industrial Presses

Industrial Press

Industrial Presses ‒ Guardian of the Pressure

To generate maximum pressure forces comparable to a weight of up to 80,000 t, several hydraulic cylinders often work together in industrial presses. These cylinders are pressurized with up to 30 MPa via the operating medium. Electrically driven high-performance pumps ensure stable operating pressure.

Hydraulic cylinder

Sealing Systems That Are up to the Task

Whether high pressures, long strokes, high cycle rates combined with short travel distances, large diameters or excellent gap bridging, the operating conditions for seals in hydraulic cylinders for industrial presses are manifold and always challenging. In addition, robust, long-lasting and easy-to-install sealing solutions are required. In the event of repairs, rapid availability is desired, as is the possibility of individual adaptation to existing installation spaces.

Seals and sealing systems from Freudenberg Sealing Technologies have been reliably meeting these requirements for decades. Market leaders in the industry trust Freudenberg Sealing Technologies quality seals.

Sealing Systems for Plunger Main Cylinders

Plunger

No chance for unwanted pressure buildup

A proven standard sealing system is predominantly used in a plunger cylinder. Large diameters and high system pressures with long strokes are the norm here. The pressure-relieved Merkel® Omegat primary rod seal takes on the important task here of preventing excessive pressure buildup in the space between the primary and secondary seals due to drag oil. A possible risk of extrusion for both sealing elements and thus failure of the sealing system is averted.

Typical application fields: Metal forming presses; Chipboard presses; Tube forming presses.

Typical operating conditions:
Rod Diameter: 700 mm
Movement: Linear, downward stroke
Pressure: 30 MPa
Speed: Loaded: 0,02 m/s; Load-free: 0,5 m/s
Stroke: Loaded: 400 mm; Load-free: 2500 mm
Medium: Mineral Oil

Plunger

When things get hot and dusty

If environmental influences such as dirt and liquids or radiant heat play a role, a special wiper made of PTFE is used in the proven standard sealing system for the plunger cylinder. The double wiper Merkel® PT2 with housing-enclosing geometry reliably protects the sealing component behind it from contamination. This sealing solution also allows the cylinder to be arranged with the rod extending upwards.

Typical application fields: Chipboard presses; Short-cycle presses; Stone and ceramic presses; Up-stroke presses.

Typical operating conditions:
Rod Diameter: 700 mm
Movement: Linear, upward stroke
Pressure: 30 MPa
Speed: Loaded: 0,02 m/s; Load-free: 0,5 m/s
Stroke: Loaded: 400 mm; Load-free: 2500 mm
Medium: Mineral Oil

Plunger

For water-based hydraulic fluids

If flame-retardant hydraulic fluids (HFA) are used to operate a plunger cylinder, the standard sealing system is trimmed for hydrolysis resistance. This means that only sealing elements made of elastomer or PTFE materials are used. Even the static cover seal is designed as an O-Ring with a PTFE backup ring.

Typical application fields: Forging presses; Metal forming presses; Particle board presses.

Typical operating conditions:
Rod Diameter: 700 mm
Movement: Linear, downward stroke
Pressure: 30 MPa
Speed: Loaded: 0,02 m/s; Load-free: 0,5 m/s
Stroke: Loaded: 400 mm; Load-free: 2500 mm
Medium: Water Emulsion (HFA)

Plunger

For shortest control strokes

During short strokes of a plunger cylinder, no sufficient oil film is built up under the sealing edges and the guide elements. Suitable seal materials from our portfolio and special guides are the answer to this type of poor lubrication. The convex geometry of our Merkel® Guivex guide facilitates the intake of operating medium for sufficient lubrication of the guide element even with the shortest strokes.

Typical application fields: Continuous particleboard presses, Fine blanking presses.

Typical operating conditions:
Rod Diameter: 400 mm
Movement: Linear, upward stroke
Pressure: 26 MPa
No. of cycles: 60/min
Stroke: 2 mm up to 10 mm
Medium: Mineral Oil

Plunger Sealing Solutions for the MRO Market

Plunger

Optimized V-Packing Set

The modern polyurethane pressure ring in the Merkel® ES81 roof collar set scores points in several ways:

  • Increased sealing effect
  • Additional static sealing edge against the ingress of air
  • Favorable friction behavior
  • High resistance to gap extrusion

Typical application fields: Down-stroke presses; Short cycle presses.

Plunger

Large diameter, rough operation

Hard usage often goes hand in hand with a highly stressed surface of the cylinder rod. This is where a Merkel® V-Packing Set V1000 shows its strength. The seal set is resilient to scratches and wear and still provides good gap bridging even at high pressure and increased guide clearance. If open installation and tolerance to dust & dirt are also on the to-do list, the re-adjustable Merkel® V-Packing Set V1000 is the first choice.

Typical application fields: Large-size presses.

Plunger

From old to new

The modern Merkel® cassette solution is a potential replacement for older V-packing sets in plunger cylinders. The driving forces for a retrofit are:

  • Higher sealing performance requirements
  • Favorable friction characteristics for greater control accuracy, short cycle times, and high speeds
  • Constant long-term behavior
  • Easier installation

Typical application fields: Retrofit; When requirements change.

Sealing Systems for Differential Main Cylinders

Differential 1

Long strokes under control

Under normal operating conditions, the standard sealing system for a differential main cylinder consists of the most advanced components in the Freudenberg Sealing Technologies product portfolio. They offer features such as

  • Merkel® Omegat OMS-MR PR primary seal for maximum extrusion protection
  • Merkel® T20 polyurethane secondary seal for low friction and minmal residual oil film on the rod
  • Polyurethane double wiper with long service life
  • Merkel® Guivex guide bands for highest loads

Typical application fields: Downstroke presses; Metal forming presses; Bending presses; Working cylinders.

Typical operating conditions:
Rod Diameter: Rod: 200 mm; Piston: 250 mm
Movement: Linear, downward stroke
Pressure: Rod: 16 MPa; Piston: 30 MPa
Speed: Loaded: 0,01 m/s; Load-free: 1 m/s
Stroke: Loaded: 200 mm; Load-free: 1600 mm
Medium: Mineral Oil

Differential 2

Taking the scare out of rough conditions

In order to avoid metallic contact between the moving and static parts, large gaps are generally used, especially under harsh ambient conditions, high operating pressures or pressure peaks. The sealing system of a differential cylinder must therefore be particularly robust and bridge large sealing gaps. A Merkel® ES61 V-packing set with bronze pressure ring masters these challenges.

Typical application fields: Baling presses; Scrap presses.

Typical operating conditions:
Diameter: Rod: 200 mm; Piston: 280 mm
Movement: Linear, horizontal stroke
Pressure: Rod: 10 MPa; Piston: 30 MPa
Speed: 0,3 m/s
Stroke: Up to 10,000 mm
Medium: Mineral Oil

Sealing Systems for Car Body Presses

Sealing system for car body presses

For oiled air as operating medium

A compact polyurethane sealing system is used for this type of cylinder and operating medium. The proven Merkel® TMP20 U-Cup and the TMP21 version for the piston show their strengths at moderate pressures but high stroke speeds.

Typical application fields: Balancing cylinder; Drawing cushion.

Typical operating conditions:
Diameter: Rod: 100 mm; Piston: 600 mm
Movement: Linear, downward stroke
Pressure: Rod: 2 MPa
Speed: 1,5 m/s
Stroke: 1500 mm
Medium: Lubricated air, initial lubrication

Sealing system for car body presses

For dry air as operating media

Mastering fast, long strokes without lubrication is always a worst-case scenario for the sealing system of a differential cylinder. The PTFE glass compound of the Freudenberg Sealing Technologies sealing and wiper elements masters this task. A Merkel® Guivex guide band shows its particular strength in this application. The convex outer geometry of the band distributes the load evenly and prevents the usual edge pressure. Thus, the initial lubrication is sufficient for a long service life.

Typical application fields: Balancing cylinder; Drawing cushion.

Typical operating conditions:
Diameter: Rod: 100 mm; Piston: 600 mm
Movement: Linear, downward stroke
Pressure: Rod: 2 MPa
Speed: 2 m/s
Stroke: 1500 mm
Medium: Dry air, initial lubrication

    Industrial Presses Downloads

  • Brochures 66-plus 67-minus

    52-filetype-pdf

    Sealing Solutions for Industrial Presses

    Freudenberg Sealing Technologies supplies compact sealing systems – among others comprising the well known seals of the Merkel® product brand – that ensure reliable sealing even under the extreme conditions encountered in the wide field of industrial presses.

    English | PDF | 8016 KB

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