SITEMA PowerStroke · is pre-loaded and ready for the closing stroke. Proximity switch 2...

Locking, actuating and releasing by hydraulic pressure

SITEMA PowerStroke FSK

Technical Information

TI-P11-EN-01/2019

Technical Information TI-P11

SITEMA PowerStrokeMold closing devices series FSK

drive system for powerful forces on a short stroke

hydraulic actuation

closing force up to 180 tonnes

option FSK-SVE: For rods that move in and out

1/8SITEMA GmbH & Co. KG . G.-Braun-Straße 13 . D-76187 Karlsruhe . Phone: +49(0)721/98661-0 . Fax: -11 . www.sitema.com

Contents1 Function..................................................................... 12 Applications .............................................................. 13 FSK and FSK-SVE..................................................... 14 Function description ................................................ 25 Installation instructions ........................................... 46 Overview FSK types in standard design ................ 77 Overview FSK-SVE types in standard design........ 8

1 FunctionThe mold closing device PowerStroke series FSK clamps andactuates a rod in one direction (closing direction). A force proportional to the operating pressure is exerted tothe rod by friction.A detailed description regarding control and use of thePowerStroke FSK is given in the “Assembly Instructions MA-P11”.

2 ApplicationsThe PowerStroke FSK with its integrated short stroke cylinderis typically used in:

• blow molding to close and press the mold• injection die molding to close and generate the closing

force• other applications requiring powerful forces on a short

stroke

3 FSK and FSK-SVEIn addition to the standard design FSK, the FSK-SVE optionis also available (SVE is a combination of German wordsmeaning “rod exits the unit”). With the FSK-SVE option, therod is permitted to move in and out between the opening andclosing strokes.The FSK-SVE option has a hardened centering ring that cen-ters the rod in relation to the clamping system. The rod openings in the standard design FSK are equippedwith guiding strips and wipers.

Fig. 1: Application example: Schematic diagram of mold press with 4 x SITEMA PowerStroke FSK

Fig. 2: Application example: Option for rods that move in and out with 4 x SITEMA PowerStroke FSK-SVE




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4 Function descriptionThe following function description refers to a case where thePowerStroke FSK is mounted on the moving machine ele-ment. The rod acts as a connection to the stationary machineelement. The closing direction is shown as it would appear inthis case.Alternatively, the PowerStroke FSK can also be mounted onthe stationary machine element. In this case, the rod is mov-ing and the closing direction is reversed.

Fig. 3: Operating states of the SITEMA PowerStroke FSK (an animation of operation can be found at www.sitema.com)

4.1 Design

Fig. 4: Design: SITEMA PowerStroke FSK

The clamping system consists of the clamping sleeve (b)Fig. 4 and the clamping ring (d), Fig. 4, which are bracedagainst each other by a separate pre-loading piston (c)Fig. 4. The clamping ring is mounted in the housing (a), Fig. 4on moving bearings, and can be moved hydraulically via thepressure ports L and K.The pre-loading piston is supplied with pressure via pressureport V.

H For special designs, springs can be used instead of thepre-loading piston. In this case, the clamping sleeve (b)Fig. 4 and clamping ring (d), Fig. 4 are braced againseach other by springs. The clamping system is kept openby pressurization of port L and the rod is clamped when Lis no longer under pressure (no port V).

2LK

323

V

2LK323

V

2LK323

V

PowerStroke FSK on the moving machine element

1. Clamping is released, PowerStroke FSK

2. Clamping the rod

3. Executing the

.

closing direction (stationary rod)

closing stroke

closing stroke

can be moved in closing direction c

2LK

3

V23

closing direction(stationary rod)

a

b

d

c





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4.2 Releasing the clamping

Fig. 5: SITEMA PowerStroke FSK on moving machine part; state when clamping released

If pressure port L receives the required operating pressure(pressure ports K and V not under pressure), the housing (a),Fig. 5 moves against the closing direction as far as the stopand opens the clamping system (see Fig. 5).Proximity switch 2 signals “clamping released”.

JWARNING!Danger due to overpressure!A pressure relief valve is required to prevent an inadmis-sible level of overpressure. A pressure control valve withdownstream check valve is advisable, to avoid suddendrops in pressure.

4.3 Clamping the rod

Fig. 6: SITEMA PowerStroke FSK on the moving machine part; state when clamping commences

If pressure to pressure port L is switched off and the requiredoperating pressure is applied to pressure port V (no pressureat pressure port K), the PowerStroke clamps the rod. The unitis pre-loaded and ready for the closing stroke.Proximity switch 2 “clamping released” is no longer active.

4.4 Executing the closing stroke

Fig. 7: SITEMA PowerStroke FSK on the moving machine part; state when closing stroke ends

To execute the closing stroke, pressure is applied both topressure port K and pressure port V when the rod is clamped.The clamping force is then self-intensifying and increases,and the housing moves in the closing direction.The closing stroke ends when the force corresponding toclosing pressure at pressure port K is reached.

H If no counter force from the machine/system acts on thePowerStroke FSK during the closing stroke, thePowerStroke FSK travels the maximum closing strokeand the internal end stop is reached. Then, depending onthe version and operating conditions, the clamping sys-tem may open so the rod is no longer clamped.

If the PowerStroke travels the maximum closing stroke, prox-imity switch 3 signals the error message “stroke limitreached”. This signal must not be displayed during normal op-eration (see chapter 5.6 „Operating conditions“ on page 6).The proper function of the PowerStroke FSK can be moni-tored continuously by proximity switches 2 and 3.To release the clamping, pressure port K and V are depres-surized and pressure is applied to pressure port L. The hous-ing moves back by the amount of the closing stroke justperformed, and the clamping of the rod is released.

2LK

3

V23

closing direction(stationary rod)

b ca

d

2LK

3

V23

2LK

323

V


executed closing stroke





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5 Installation instructions

5.1 MountingThe PowerStroke FSK is integrated in the system via themounting side (see “Assembly Instructions MA-P11”). Duringinstallation, make sure that no constraint forces occur trans-verse to the rod. Often, this cannot be guaranteed through ex-act alignment or high-precision machining alone.J Constraint forces transverse to the rod can create in-

creased material stress and can damage both the PowerStroke FSK and the clamping rod.

Vertical installation of the standard design FSK:In order to avoid constraint forces transverse to the rod, eitherthe PowerStroke FSK must be screwed radial loosely ontothe machine part, or the rod or rod connection must be radialloosely screwed on. For vertical installation of thePowerStroke FSK, an FSK vertical attachment can also beused (device to compensate a radial rod misalignment). Theadmissible radial misalignment when using a FSK vertical at-tachment in the standard design is ±1 mm (see “TechnicalData Sheet TI-P30”).

Vertical installation of the FSK-SVE option: With the FSK-SVE, for rods that move in and out, the FSKvertical attachment is required for vertical installation of thePowerStroke in the machine/system. The admissible radialmisalignment when using a FSK vertical attachment in thestandard design is ±1 mm (see “Technical Data Sheet TI-P30”).

Horizontal installation of the FSK and FSK-SVE: To achieve error-free alignment, appropriate measures mustbe taken during attachment, e.g. connecting the rod radialloosely if possible. Please consult SITEMA if necessary.

H When using the FSK vertical attachment, please payattention to the different technical data concerning thetotal length and max. extended length, see “TechnicalData Sheet TI-P30”.

5.2 Design of the rodThe PowerStroke FSK will operate correctly only if the rodhas a suitable surface:

• ISO tolerance field f7 or h6• induction hardened min. HRC 56, surface hardening

depth:ø up to 30 mm: min. 1 mmø over 30 mm: min. 1.5 mm

• surface roughness: Rz = 1 to 4 μm (Ra 0.15 - 0.3 μm)• protection against corrosion, e.g. hard chromium plating

20 ±10 μm, 800 – 1 000 HV• lead-in chamfer, rounded

with FSK (standard design):ø 18 mm up to ø 80 mm: min. 4 x 30 °ø over 80 mm up to ø 180 mm: min. 5 x 30 °ø over 180 mm up to ø 380 mm: min. 7 x 30 °with FSK-SVE: (option for rods that move in and out):ø 18 mm bis ø 80 mm: min. 8 x 10 °ø über 80 mm bis ø 180 mm: min. 12 x 10 °ø über 180 mm bis ø 380 mm: min. 15 x 10

Often, the following standard rods fulfill the above mentionedrequirements and can then be used:

• piston rods (ISO tolerance field f7), hard chrome plated• rods for linear ball bearings (ISO tolerance field h6)

The rod may not be lubricated with grease.

H Generally, the basic rod material has to have sufficienyield strength. Ensure that there is no risk of buckling incase of compression-loaded rods.

5.3 Pressure fluidHydraulic oil (HLP) in accordance with DIN 51524-2:2017must be used as pressure fluid. Please consult SITEMAbefore using any other fluids.





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5.4 ActuationConnect the pressure supply to pressure ports L, K and V(alternatively LL, KK and VV). We recommend connectingauto-bleeders (8), Fig. 8 (not in scope of delivery; available asoptional extras, see “Technical Information TI-Z10”) to thepressure ports that are not in use (or to the supply pipes ofthe used pressure ports).

Fig. 8: Basic diagram of actuation

Pressure controlThe flow rate and pressure at pressure port L and K can bevariably adjusted in line with specific usage by means of theproportional valve (1), Fig. 8. If the pressure (p), Fig. 8 is not sufficiently constant (e.g. sud-den drops in pressure at the beginning of lowering motions),a check valve is recommended (2), Fig. 8 in the port p of thevalve.

Pressure port L “release”Pressure port L must be kept continually under operatingpressure while the rod is in motion or is being inserted. Thisopens the clamp, see chapter 4.2 „Releasing the clamping“ onpage 3.

H Requirements for the hydraulic systemThe hydraulic system must be capable of providing themaximum pressures specified in the technical data (seetechnical data at page 7 and page 8).

Pressure port V “pre-load pressure”Pressure port V must be kept continually under the requiredoperating pressure to activate the clamping action or duringthe closing stroke. Also see chapter 4.3 „Clamping the rod“on page 3.

H Pressure relief valve, pressure control valve, pressure accumulatorIn order to avoid overpressure due to interactions withother pressure chambers, a pressure relief valve (4),Fig. 8 is required. A pressure control valve (3), Fig. 8 isrecommended to ensure energy-efficient adaptation ofthe system pressure to the required pressure at port V. Acheck valve (5), Fig. 8 ensures that the pressure in thepressure accumulator, which is required for reliable pre-loading, is maintained even in the event of sudden dropsin pressure.

Pressure port K “closing stroke”If the rod is fully inserted and there is no pressure at pressureport L and pressure application at pressure port V (monitoringby pressure sensor (7), Fig. 8) then pressure port K can bepressurized. The applied pressure at pressure port K thencauses the execution of the closing stroke and the creation ofthe appropriate closing force. Also see chapter 4.4 „Executingthe closing stroke“ on page 3.

Notes:H We recommend relieving pressure port V of pressure

when pressure is applied to pressure port L, to minimizematerial stress. If pressure is still applied to pressure portV while pressure port L is in operation, part of the clamp-ing force could be used to force open a tool, for example.

JPressure ports L and K must never have pressureapplied to them simultaneously.

H The releasing, pre-load or closing force is proportional tothe pressure: the lower the pressure applied to executethe function, the lower the material stress. Applying thelowest possible pressure to the PowerStroke FSK helpsto achieve a long service life.

The customer must set up the hydraulic actuation in accor-dance with the applicable safety regulations, with the aid ofthe circuit diagram shown above.This primarily shows the logical connections. The manufac-turer is responsible for adherence to the applicable regula-tions and also for the final check of all functions.

H Clamping with the PowerStroke FSK during the move-ment due to the primary drive must be avoided becausethis could create high dynamic braking forces. Therefore,it may be necessary to take precautions against an un-wanted drop in pressure at port L.

If a short reaction time of the PowerStroke is required, com-pliance with the following requirements is essential:

• short lines• suitably large valve and line cross-sections• fast valve response times• suitable control

PI





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5.5 Status monitoring by proximity switchesThe “clamping released” signal from proximity switch 2 indi-cates an open clamping system and is used to enable themovement of the drive (or of the in-and-out movement of therod in the FSK-SVE option).The “stroke limit reached” (error message) signal from prox-imity switch 3 indicates that the maximum closing stroke hasbeen passed and the internal limit stop has been reached.The full closing force is not available in this case. Also seechapter 4.4 „Executing the closing stroke“ on page 3.

Notes:1. In the standard design, the rod must not exit the

PowerStroke FSK during operation.2. The rod may exit the PowerStroke FSK-SVE between

the closing strokes. All sizes of the standard design FSKare available as the FSK-SVE option.The following additionally applies to the PowerStrokeFSK-SVE:

HThe rod may only move into or out of the PowerStrokeFSK-SVE on the centering ring side when the clamp-ing system is released (pressure applied, proximityswitch 2 active).

HBefore pre-loading and clamping, the rod must be re-tracted by at least the minimum insertion depth. Theminimum insertion depth of the PowerStroke FSK-SVE is listed in the data sheet, in special designs inthe dimensional drawing.

3. When the clamping is released, the rod must not be ex-posed to any tensile or compressive forces. This must betaken into consideration for primary drive actuation.

4. For vertical applications: The primary drive must apply aforce that holds the weight of the moving machine partand attached components (weight compensation) duringthe return stroke and release process. This prevents themoving machine part from sinking after the clamp is re-leased.

5.6 Operating conditionsThe immediate environment of the PowerStroke in itsstandard design must be dry and clean. Environmental contamination, such as grease, dirt, grindingdust, chips require special protective measures. Liquids suchas coolants, conservation agents and other liquids orchemicals inside the housing may reduce the holding force. It is particularly important not to apply grease to the rodbecause lubricants influence the clamping force.

• The machine manufacturer must take measures to en-sure that contamination cannot enter the interior of thehousing.

• In case of doubt, please contact SITEMA.The permitted surface temperature is 0 to +60 °C.

5.7 CE markingThe PowerStroke FSK is designed as a component (partlcompleted machinery) to be integrated into a machine osystem and as such can never be CE marking itself. Thseller of the machine or system must provide information othe PowerStroke FSK with the overall documentation and applicable ensure that the machine or system is CE certified





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6 Overview FSK types in standard design

Fig. 9: Dimensions SITEMA PowerStroke series FSK

Subject to modification without prior notice

1 Proximity switch holders are provided for standard inductive proximityswitches (flush mountable, NO (normally open), M8 x 1 with a nominal switch-ing distance of 1.5 mm).For easier service, the proximity switch holders have a depth stop and are pre-adjusted when delivered from the factory. The switches only need to be insert-ed to the stop and then clamped.

The proximity switches are not included in the standard scope of delivery butare available as accessories.2 The surface of the housing parts is primed black, the mounting side is treat-ed with corrosion protection wax.

Type FSK 45 FSK 70 FSK 100 FSK 125 FSK 160 FSK 180 FSK 200ID no. (order no.) FSK 045 10 FSK 070 10 FSK 100 10 FSK 125 10 FSK 160 10 FSK 180 10 FSK 200 10Closing force at max. closing pressure at K kN 60 110 300 650 1000 1400 1800Technical dataRod diameter [d] mm 45 70 100 125 160 180 200Lead-in chamfer [C] mm 4 4 5 5 5 5 7Outer diameter [A] mm 160 198 268 328 417 476 546Total length [H] mm 310 353 450 600 700 770 865Max. extended length [HE] mm 341 384 483 633 736 806 903Max. closing stroke mm 20 20 20 20 20 20 20Weight approx. kg 40 62 145 240 460 650 930Hydraulic dataMax. closing pressure at K bar 100 100 125 200 200 200 200Hydraulic operating volume K with overall stroke cm³ 195 350 805 1080 1900 2550 3400Min. release pressure at L bar 75 75 100 160 160 160 180Max. release pressure at L bar 100 100 170 250 200 230 220Max. hydraulic operation volume L cm³ 85 150 215 320 750 850 1250Min. pre-load pressure at V bar 75 75 100 160 160 160 180Max. pre-load pressure at V bar 100 100 125 200 200 200 200Max. hydraulic operating volume V cm³ 15 40 60 105 160 190 320Connection dimensionsHK mm 49 57 97 103 117 112 119HL mm 135 140 195 188 231 227 236H2 mm 200 213.5 286 282 379.5 406 412H3 mm 193.5 206 276 274 371 394.5 404HT1 mm 174 189 21.5 17 26 24 35AG G1/4 G3/8 G1/2 G1/2 G3/4 G3/4 G3/4AGT1 G1/8 G1/8 G3/8 G3/8 G3/8 G3/8 G1/2AGT2 – – G1/8 – G1/4 G3/8 G3/8AGV G1/8 G1/8 G1/8 G1/8 G1/4 G3/8 G3/8Z mm 88 117 148 195 235 248 278X mm 15 15 38 42 42 42 42L1 mm 110 140 180 235 275 300 335w 6 x 60° 6 x 60° 6 x 60° 6 x 60° 8 x 45° 10 x 36° 10 x 36°v 30° 30° 30° 30° 22.5° 18° 18°G M10 M12 M16 M20 M20 M24 M30T mm 16 20 25 32 32 40 50

2 0 °

H

HK

G

H LH T 1H 3H 2

HE

v

w

A G AG AG T 1

A G AGVAG

øZe8

ødf7/h6

øL1

øA

X - 0 , 2X - 0 , 2

m i n . C x 3 0 °

v

w

A G VAG T 2T

Pressure port K “closing stroke”

Pressure port L “clamping released”

Pressure port V“pre-load pressure”

Holder for proximity switch 2,signal “clamping released” see 1Holder for proximity switch 3,signal “stroke limit reached” see 1

K

2

V

L

3


2




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7 Overview FSK-SVE types in standard design

Fig. 10: Dimensions SITEMA PowerStroke series FSK-SVE

Subject to modification without prior notic

1 Proximity switch holders are provided for standard inductive proximityswitches (flush mountable, NO (normally open), M8 x 1 with a nominal switch-ing distance of 1.5 mm).For easier service, the proximity switch holders have a depth stop and are pre-adjusted when delivered from the factory. The switches only need to be inserted to the stop and then clamped.

The proximity switches are not included in the standard scope of delivery buare available as accessories.2 The surface of the housing parts is primed black, the mounting side is treaed with corrosion protection wax.

Type FSK-SVE 45 FSK-SVE 70 FSK-SVE 100 FSK-SVE 125 FSK-SVE 160 FSK -SVE180 FSK-SVE 20ID no. (order no.) FSK 045 11 FSK 070 11 FSK 100 11 FSK 125 11 FSK 160 11 FSK 180 11 FSK 200 11Closing force at max. closing pressure at K kN 60 110 300 650 1000 1400 1800Technical dataRod diameter [d] mm 45 70 100 125 160 180 200Lead-in chamfer [C] mm 8 8 12 12 12 12 15Min. insertion depth [HM] mm 220 250 350 475 585 660 735Outer diameter [A] mm 160 198 268 328 417 476 546Total length [H] mm 310 353 450 600 700 770 865Max. extended length [HE] mm 341 384 483 633 736 806 903Max. closing stroke mm 20 20 20 20 20 20 20Weight approx. kg 40 62 145 240 460 650 930Hydraulic dataMax. closing pressure at K bar 100 100 125 200 200 200 200Hydraulic operating volume K with overall stroke cm³ 195 350 805 1080 1900 2550 3400Min. release pressure at L bar 75 75 100 160 160 160 180Max. release pressure at L bar 100 100 170 250 200 230 220Max. hydraulic operation volume L cm³ 85 150 215 320 750 850 1250Min. pre-load pressure at V bar 75 75 100 160 160 160 180Max. pre-load pressure at V bar 100 100 125 200 200 200 200Max. hydraulic operating volume V cm³ 15 40 60 105 160 190 320Connection dimensionsHK mm 49 57 97 103 117 112 119HL mm 135 140 195 188 231 227 236H2 mm 200 213.5 286 282 379.5 406 412H3 mm 193.5 206 276 274 371 394.5 404HT1 mm 174 189 21.5 17 26 24 35AG G1/4 G3/8 G1/2 G1/2 G3/4 G3/4 G3/4AGT1 G1/8 G1/8 G3/8 G3/8 G3/8 G3/8 G1/2AGT2 – – G1/8 – G1/4 G3/8 G3/8AGV G1/8 G1/8 G1/8 G1/8 G1/4 G3/8 G3/8Z mm 88 117 148 195 235 248 278X mm 15 15 38 42 42 42 42L1 mm 110 140 180 235 275 300 335w 6 x 60° 6 x 60° 6 x 60° 6 x 60° 8 x 45° 10 x 36° 10 x 36°v 30° 30° 30° 30° 22.5° 18° 18°G M10 M12 M16 M20 M20 M24 M30T mm 16 20 25 32 32 40 50

2 0 °

øZe8

G

H LH T 1H 3H 2

w

A G AG AG

AG AG

ødf7/h6

øL1

øA

H KT

v

w

A G V

m i n . HM

HX - 0 , 2 H E

v

m i n . C x 1 0 °

A G VAG T 2

Pressure port K “closing stroke”

Pressure port L “release”

Pressure port V“pre-load pressure”

Holder for proximity switch 2signal “clamping released” see 1Holder for proximity switch 3signal “stroke limit reached” see 1

K

2

V

L

3


2


SITEMA PowerStroke · is pre-loaded and ready for the closing stroke. Proximity switch 2...

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