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Hydraulic Locking Core Pull Cylinders
User Manual
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DME Hydraulic Locking Core Pull Cylinders User Manual

DME HYDRAULIC LOCKING CORE PULL CYLINDERS Specification No. ME-E32-0001(C) Part No. HLCP-PS01 Page 1 of 12
IMPORTANT SAFETY INFORMATION
1. To avoid injury, exercise caution by reading these instructions before servicing or operating the system.
2. These instructions must be passed on to the end user where they should be read before using this product. Failure to do so can result in injury.
Failure to comply can result in injury:
STORED ENERGY HAZARD
2. Hydraulic service to the cylinder assembly must not exceed 3625 PSI hydraulic pressure.
Failure to comply can result in improper equipment operation or damage:
1. The DME Hydraulic Locking Core Pull Cylinder (HLCP) assembly includes two inductive proximity sensors at low power. The proximity sensors require power to deliver a signal. It is the responsibility of the customer to provide proper electrical service for sensor operation.
2. The proximity sensors require proper adjustment while installing into the cylinder assembly, as each sensor must be installed to a different depth. Please follow the provided sensor installation instructions properly, or else the cylinder may not operate properly, or, the sensors will fail to detect the proper position of the piston.
3. The proximity sensors are available in two types: NPN (standard) or PNP (optional). If PNP type is required, this must specified at system order. Electrical wire-up schematics are provided for both types in this document. Please follow the proper wire-up for the proximity sensor.
4. If the proximity sensors are not used, it is always important to monitor the position of the sliding core. External limit switches may be used if the machine cannot deliver power to the sensors, or where the service temperature of the proximity sensors is expected to be exceeded, or in cases were an elevated level of magnetism or electrical current is expected to be in close proximity to the sensors. For proper system function, it is important that full forward (extended) position as well as the full reverse (retracted) position of the piston (or sliding core) be monitored.
5. If using the proximity sensors provided with this device, do not exceed the maximum service temperature of 176°F (80° C).
6. When using external limit switches in the mold instead of the proximity sensors supplied with this product, the maximum service temperature of this device is 356°F (180° C).
7. A minimum of 870 PSI holding pressure (hydraulic service) is required at all times. If the 870 PSI holding pressure is not maintained while the piston is in full forward (extended position), the piston may not remain locked in forward position within the cylinder assembly.
8. The Mold Designer and/or Mold Maker is required to select the proper size of cylinder assembly in order to counter load that will act on the sliding core due to plastic injection pressure within the mold cavity. Improperly selected cylinder assembly size can result in molded part flash or damage to the mold during operation.
9. When selecting the appropriate size of cylinder assembly, take care to account for the necessary preload when the sliding core needs to shut off on an opposing core face inside the mold. Load capacity of the cylinder assembly is reduced when preload of the sliding core is required. The recommended preloads for each cylinder assembly size are provided in this document, as well as load capacities for both with and without preload.
10. The piston rod is not to be used as the sliding core itself. Do not modify the piston rod in any way. The piston rod is intended to be attached to the sliding core in the mold, and it is the responsibility of the mold designer and/or mold maker to select appropriate sliding core design for the intended application.
DETAIL 1.0: HYDRAULIC LOCKING CORE PULL CYLINDER ASSEMBLY Note: Spacer disk not shown
MOLD DESIGN CONSIDERATIONS:
This product is available in several sizes, and each size has a two available “standard” stroke lengths. If you require a stroke that is different than the
available standard strokes, then a non-standard stroke design is required. When ordering this product, please specify the required stroke if the standard strokes available are not suitable for the intended application.
This product maintains a sliding core in full back (retracted) or full forward (extended) positions. In order for the cylinder assembly to “lock”, the piston
must be full extended forward.
This product includes a spacer disk. The spacer disk is placed between the front of the body flange and pocket installation. The mold maker must grind
the spacer disk to ensure proper fit at the desired mold operation temperature. The adjustment of the spacer disk is important for when the sliding core
DME HYDRAULIC LOCKING CORE PULL CYLINDERS Specification No. ME-E32-0001(C) Part No. HLCP-PS01 Page 2 of 12
MOLD DESIGN CONSIDERATIONS (continued):
must “shut off” against an opposing core wall or face, so that plastic flashing is avoided. For proper “shut-off” as described above, recommended preload amounts are provided in this document. Adjust the spacers prior to final mold assembly. Ensure sufficient pocket clearance around the piston rod and spacer disk is present for smooth operation.
Positional alignment of the cylinder assembly is achieved by aligning the forward collet of the cylinder body (protrudes forward of the mounting flange)
into the mold plate via the outer diameter of the collet. The collet will protrude past the spacer disk. Rotational alignment of the overall assembly is achieved via the mounting screws, as rotational alignment is only used to position the proximity sensors and hydraulic fitting connections and/or hoses within the overall installation. The piston may freely rotate, therefore if rotational alignment of the sliding core is required, rotational alignment of the sliding core must be achieved via other means.
The positional alignment of the mold’s sliding core is not to be maintained by the cylinder assembly’s piston. The sliding core must have it’s own
provision for positional alignment within the mold plate.
The suggested installation pocket details are based on the cylinder assembly being recessed into the side of the mold plate. It is possible to have the
cylinders assembly mounted fully “proud” of the side of the mold plate, however, positional alignment of the cylinder assembly to the mold plate requires the forward collet (protruding forward of the mounting flange of the cylinder body) to be recessed partially into the side of the mold. Please adjust the overall installation as required to fit your application, while maintaining minimum clearances for the hydraulic fitting connections and/or hoses, as well as maintaining clearances for the proximity sensors. It is the responsibility of the mold designer and/or mold maker to select appropriate hydraulic fittings, as well as provide necessary pocket clearances (where required) for the hydraulic fittings. Clearance for hydraulic service may need to accommodate hoses or other features, in addition to the hydraulic fittings themselves. Standard hydraulic thread is NPTF type, but other types are available upon request.
Please see Detail 3.4 for additional notes regarding necessary clearance needed to accommodate the proximity sensors. Mounting screws provided should not be modified (shortened). Ensure the tapped mounting holes are deep enough to ensure the screw heads can fully
seat on the mounting flange after the screws are installed fully and torque is applied.
SEE NEXT PAGES FOR SUGGESTED POCKET MACHINING DETAILS
DETAIL 1.1 - HYDRAULIC LOCKIN CORE PULL ASSEMBLY
TABLE 1.0 — HLCP ASSEMBLY SIZES
ASSEMBLY No. STROKE ROD DIA. CYLINDER BORE DIA.
HLCP060-1000 25.4 mm (1.00 in) HLCP060-2000 50.8 mm (2.00 in) HLCP100-1250 31.8 mm (1.25 in) HLCP100-2500 63.5 mm (2.50 in)
HLCP150-1375 34.9 mm (1.375 in)
HLCP150-2750 69.9 mm (2.75 in) HLCP200-1750 44.5 mm (1.75 in) HLCP200-3500 88.9 mm (3.50 in) HLCP300-2000 50.8 mm (2.00 in) HLCP300-4000 101.6 mm (4.00 in) HLCP500-2500 63.5 mm (2.50 in) HLCP500-5000 127.0 mm (5.00 in) HLCP750-3000 76.2 mm (3.00 in) HLCP750-6000 152.4 mm (6.00 in)
16 mm
(0.63 in)
20 mm
(0.79 in)
25 mm
(0.98 in)
32 mm
(1.26 in)
42 mm
(1.65 in)
50 mm
(1.97 in)
60 mm
(2.36 in)
30 mm (1.18 in) 1/8
36 mm (1.42 in) 1/8
45 mm (1.77 in) 1/4
56 mm (2.20 in) 1/4
71 mm (2.80 in) 3/8
84 mm (3.31 in) 3/8
105 mm (4.13 in) 1/2
NPTF
TAP
TABLE 1.1 — LOAD CAPACITIES FOR THE DME HYDRAULIC LOCKING CORE PULL CYLINDER ASSEMBLY
AT 160 BAR
ASSEMBLY NUMBER
(2321 PSI) PRELOAD
HLCP060-1000 0.15 mm (0.006 in) HLCP060-2000 0.20 mm (0.008 in) HLCP100-1250 0.15 mm (0.006 in) HLCP100-2500 0.20 mm (0.008 in) HLCP150-1375 0.10 mm (0.004 in) HLCP150-2750 0.15 mm (0.006 in) HLCP200-1750 0.15 mm (0.006 in) HLCP200-3500 0.20 mm (0.008 in) HLCP300-2000 0.15 mm (0.006 in) HLCP300-4000 0.20 mm (0.008 in) HLCP500-2500 0.20 mm (0.008 in) HLCP500-5000 0.30 mm (0.012 in) HLCP750-3000 0.20 mm (0.008 in) HLCP750-6000 0.30 mm (0.012 in)
Holding Force in kilo
Newton [kN]
Without Preload
60 35 13,488 7,868 6.12 3.57 5.46 3.19 6.74 3.93
100 50 22,480 11,240 10.20 5.10 9.11 4.55 11.24 5.62
150 65 33,720 14,612 15.30 6.63 13.65 5.91 16.86 7.31
200 110 44,960 24,728 20.39 11.21 18.20 10.01 22.48 12.36
300 160 67,440 35,968 30.59 16.31 27.31 14.57 33.72 17.98
500 300 112,400 67,440 50.98 30.59 45.51 27.31 56.20 33.72
750 400 168,600 89,920 76.48 40.79 68.27 36.41 84.30 44.96
With
Preload
Holding Force in
Pound Force [lbf]
Without Preload
With
Preload
Holding Force in
Metric ton [ton]
Without Preload
With
Preload
Holding Force in UK
(troy) ton [ton]
Without Preload
With
Preload
Holding Force in US
(avdp) ton [ton]
Without Preload
With
Preload
DME HYDRAULIC LOCKING CORE PULL CYLINDERS Specification No. ME-E32-0001(C) Part No. HLCP-PS01 Page 3 of 12
MOLD DESIGN CONSIDERATIONS (continued):
TABLE 1.3 — MASSES AND THREAD SIZES
Assembly Number
Mass
kg lb
HLCP060-1000 1.8 3.97
HLCP060-2000 2.0 4.41
HLCP100-1250 2.9 6.39
HLCP100-2500 3.2 7.05
HLCP150-1375 5.0 11.02
HLCP150-2750 5.4 11.90
HLCP200-1750 9.3 20.50
HLCP200-3500 10.5 23.15
HLCP300-2000 20.1 44.31
HLCP300-4000 22.4 49.38
HLCP500-2500 31.0 68.34
HLCP500-5000 33.0 72.75
Thread Size
in Piston Rod
Thread Tap Hole Depth
to Drill Point
5/16 - 24 UNF 20mm
5/16 - 24 UNF 20mm
3/8 - 24 UNF 28mm
1/2 - 20 UNF 35mm
5/8 - 18 UNF 40mm
5/8 - 18 UNF 42mm
HLCP750-3000 55.5 122.36
HLCP750-6000 62.1 136.91
3/4 - 16 UNF 50mm
DME HYDRAULIC LOCKING CORE PULL CYLINDERS Specification No. ME-E32-0001(C) Part No. HLCP-PS01 Page 4 of 12
PROXIMITY SWITCH ELECTRICAL DATA:
Switching Output: BHS006Y = NPN (Standard), BHS006U = PNP (Special) Connection 2 m Cable (PUR)
Utilization category DC 13 Ripple max. of Ue 10 % Rated operational voltage (Ue) 24 DC V mm Operating frequency (f) 3000 Hz Load current capacity (Ie) 100 mA Voltage drop max. static 2.5 V Hysteresis max (H) 15 % No-load supply current damped 10 mA Switching element function NO No-load supply current undamped 7 mA Time delay before availability 25 ms Off-state current max (Ir) 100 μA Electrical type DC Supply voltage max. (Ub) 30 V Load capacitance max 0.4 μF Supply voltage min. (Ub) 10 V
PROXIMITY SENSOR INSTALLATION INSTRUCTIONS:
TABLE 2.0: DIMENSION “X”
HLCP150 HLCP200 HLCP300 HLCP500 HLCP750
REAR (CAP END) FRONT (FLANGE END)
[mm] [inches] [mm] [inches]
11.1 0.44 11.1 0.44
18.8 0.74 11.1 0.44
11.1 0.44 14.4 0.57
14.5 0.57 18.5 0.73
13.5 0.53 15.0 0.59
NOTE: These sensors require power to produce a signal. This includes during installation/setup and during normal operation. Refer to power requirements (above). Customer is responsible to provide power service to operate sensors. If only dry contacts are present on the injection molding machine, see next page for suggested wire-up.
A) HLCP060 & HLCP100
Rear sensor in the CAP:
1. Make sure the CYLINDER ROD is in the fully extended position.
2. Install the SENSOR into the CAP and slowly advance until the signal is lost. Be careful not to overshoot the lost position.
3. Return the CYLINDER ROD to the fully retracted position.
4. If the signal is still lost, continue to advance the SENSOR until it produces the signal again.
Advance the SENSOR one additional quarter turn.
5. Tighten the 7mm nut on the SENSOR to a torque setting of 1.0 Nm (8.9 in. lbs) to secure the SENSOR to the CAP
B) HLCP060 & HLCP100
Front sensor in the BODY:
1. Make sure the CYLINDER ROD is in the fully retracted position.
2. Install the SENSOR into the BODY and advance until the signal is lost. Be careful not to overshoot the lost position.
3. Return the CYLINDER ROD to the fully extended position.
4. If the signal is still lost, continue to advance the SENSOR until it produces the signal again.
Advance the SENSOR one additional quarter turn.
5. Tighten the 7mm nut on the SENSOR to a torque setting of 1.0 Nm (8.9 in. lbs) to secure the SENSOR to the BODY.
C) HLCP150 - HLCP750
Rear sensor in the CAP:
1. Assemble the SENSOR into the CAP SENSOR BUSHING as shown in DETAIL 2.1. The X dimension is found in
TABLE 2.0. Once the X dimension is set, use a torque setting of 1.0 Nm (8.9 in. lbs.) to secure the position of the SENSOR inside the CAP SENSOR BUSHING.
2. Make sure the CYLINDER ROD is in the fully extended position.
3. Install the SENSOR and CAP SENSOR BUSHING into the CAP and tighten until the signal is lost. Be careful not to overshoot the lost position.
4. Return the CYLINDER ROD to the fully retracted position.
5. Continue to tighten the CAP SENSOR BUSHING until it produces the signal again. Tighten the SENSOR BUSHING one additional quarter turn.
6. Tighten the nut on the CAP SENSOR BUSHING to a torque setting of 17.0 Nm (12.6 ft. lbs) to secure the CAP SENSOR BUSHING to the CAP.
D) HLCP150 - HLCP750
Front sensor in the BODY:
1. Assemble the SENSOR into the BODY SENSOR BUSHING as shown in DETAIL 2.1. The X Dimension is found in TABLE 2.0. Once the X dimension is
set, use a torque setting of 1.0 Nm (8.9 in. lbs.) to secure the position of the SENSOR inside the CAP SENSOR BUSHING.
2. Make sure the CYLINDER ROD is in the fully retracted position.
3. Install the SENSOR and BODY SENSOR BUSHING into the BODY and advance it until the signal is lost. Be careful not to overshoot the lost position.
4. Return the CYLINDER ROD to the fully extended position.
5. Continue to advance the BODY SENSOR BUSHING until it produces the signal again. Advance the SENSOR BUSHING one additional quarter turn.
6. Tighten the nut on the BODY SENSOR BUSHING to a torque setting of 17.0 Nm (12.6 ft. lbs) to secure the BODY SENSOR BUSHING to the BODY.
DETAIL 2.0: PROXIMITY SENSOR DIMENSIONS
(Shown in Millimeters)
DETAIL 2.1: PROXIMITY SENSOR BUSHING & X DIMENSION
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