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Kyntronics SHA

All-In-One actuator means a complete and fully tested electro-hydraulic actuation system including: the cylinder, attached power unit, motor, controller/drive wired on a panel or in an enclosure, our standard proven software and cables. The All-In-One solution requires only that the actuator be mounted, power connected, and external control signals provided, and the actuation system is ready to operate. In addition, documentation provided includes an interface manual, electrical schematic and a mechanical drawing outlining the specifications and requirements. The Kyntronics SMART electro-hydraulic actuator is an example of an all-in-one actuator.

This type of actuator operates at a high speed with low load, and then switches modes to operate at a high force at lower speed. It is generally used where a large amount of the stroke length is under low load and a short amount of the stroke length requires high force to do the work needed in the application. An example of this would be a metal forming press. Kyntronics offers two types of SMART electro-hydraulic actuator (SHA) configurations as high speed / high force actuators.

The SMART electro-hydraulic actuator (SHA) is a totally sealed (no air), self-contained actuator consisting of a cylinder, pump, manifold and servo motor, all in an integral package. There are no hoses or leak points on the SHA vs. a traditional hydraulic cylinder / HPU system. Functionally, the SHA retains the positive characteristics of traditional hydraulics such as high force density, tolerance for shock and side-loading, and robustness, while eliminating the negatives such as inefficiency, high energy usage, risk of leaks/environmental impact, noisy operation and difficulty/high cost to precisely control. The SHA has many advantages over traditional hydraulic systems.

The SMART electro-hydraulic actuator (SHA) is essentially an “electric actuator” that looks similar to a screw-driven actuator but rather than using gears, drive screws and driven nuts, the SHA uses an integral hydraulic cylinder with minimal fluid. Functionally, the SHA has many of the positive advantages of a screw-driven actuator such as energy efficiency / power-on-demand, precision servo control, clean operation, and fieldbus connectivity, however, the SHA eliminates the negatives of screw-driven actuators including metal-to-metal wear, need for lubrication and regular maintenance, and susceptibility to damage from shock loads.

The SMART electro-hydraulic actuator (SHA) is an ideal actuator for most industrial equipment applications. Some of the most common applications include presses, test equipment, material handling, lifting, positioning, metal fabrication, clamping and many others. Find more information on electro-hydraulic actuator applications.

Yes, there is a very significant savings opportunity using the SMART electro-hydraulic actuator (SHA) instead of traditional hydraulics. The operating cost savings is due to the following factors: the SHA is a closed system that does not require fluid replacement. Traditional hydraulics requires fluid replacement and fluid disposal as part of standard maintenance which involves hundreds of gallons annually per system. Energy usage is another cost savings advantage by using the SHA. This is due to the SHA being a “power-on-demand” device whereas traditional hydraulics run continuously and is far less efficient compared with the SHA. Other factors impacting operating costs unfavorably for traditional hydraulics include higher maintenance costs (filter replacements), downtime (burst hoses), employee safety factors (slipping from hydraulic leaks), product contamination (hydraulic fluid on parts) and requiring more floor space. For more information: pdf Select the Right Type of Actuator - Don’t Let Hidden Operating Costs Sink Your Ship

The SMART electro-hydraulic actuator (SHA) and a traditional EHA share many similar characteristics. Both have a pump, motor, valving and cylinder mounted together eliminating the hydraulic power unit, hoses and connections inherent with a typical hydraulic system. In addition, the SHA includes features such as a linear position sensor, pressure transducers, a servo motor and a control system that are used to provide precise process control for the application, and support IoT functions.

There are several control options available for the SMART electro-hydraulic actuator (SHA). The “all-in-one” solution from Kyntronics includes a servo drive/controller either in an enclosure or on a subpanel that can be mounted in the customer’s enclosure. This precision actuation solution includes standard software features developed by Kyntronics for most applications. The SHA is also provided as an “actuator only” option when the motor and drive are provided by others and Kyntronics provides the actuator with the motor mounting bracket and shaft coupling for the specific motor chosen. Common motors used on the SHA include: Rockwell Automation/Allen Bradley, Siemens, Mitsubishi, and several others.

SMART electro-hydraulic actuators (SHA) have hundreds of SHAs successful installations operating with Rockwell Automation servo motors, Kinetix drives and PLCs. Kyntronics makes it simple for the integrator and has developed an AOI for Rockwell Automation. We also provide an extensive library of tools covering hardware selection, interfacing instructions and even sample projects on the Kyntronics website.

Yes. The SMART electro-hydraulic actuator (SHA) includes a position sensor and pressure transducers for force measurement. These signals are connected to the control and used for precise process control. The Kyntronics all-in-one precision actuation system options include software to control the actuator to a specific position, or a specific force. One of the advantages of the electro-hydraulic system is the software includes functions to control position and measure force, control force and measure position, and automatically switch from controlling position to controlling force and vice-versa. The most popular control method is Position control with Force Limit – meaning it will run in position control mode until a desired force is exceeded, then seamlessly switches to controlling force. Beyond the Kyntronics all-in-one control option, the functions mentioned above are included in the Kyntronics AOI for Rockwell Automation equipment.

Yes, any standard PID control can run the SMART electro-hydraulic actuator (SHA) for many applications. Our standard software is more advanced with multiple gain sets, multiple control modes, auto tuning etc.

There are several control options available for the SMART electro-hydraulic actuator (SHA). The “all-in-one” solution from Kyntronics includes a motor and servo drive/controller in an enclosure or on a subpanel that can be mounted in the customer’s enclosure. This solution includes software features developed by Kyntronics for most applications.

The maximum force a standard SMART electro-hydraulic actuator (SHA) can produce is approximately 85,000 Lbs. (377 kN). In applications where additional force is required, multiple SHAs are mounted in parallel and precisely synchronized by the controls. Kyntronics also has high force actuators with up to 150,000 Lbs. (665 kN) for specific applications. Contact Kyntronics for special requirements outside the above.

Kyntronics produces high speed actuators. The SMART electro-hydraulic actuator’s (SHA) maximum speed is determined by the cylinder size and pump size. Desired speed / force combinations can be found on our website. See SHA specifications for additional information.

SMART electro-hydraulic actuators (SHA) are available in any 1mm length increment including long stroke actuators (generally greater than 36” (914 mm)), the SHA includes design features that increase the robustness of the actuator such as larger diameter rods, thicker cylinder tube walls, and greater rod bearing length. Kyntronics has provided actuators exceeding 120” (3,048mm). Kyntronics performs the necessary calculations to ensure robustness, prevention of buckling etc. Contact Kyntronics for your specific requirements.

The standard SMART electro-hydraulic actuator (SHA) is rated at IP65 (dynamic and static). Higher IP ratings can be provided as needed.

Yes, depending on the environment, heating or cooling can be added as needed.

The SMART electro-hydraulic actuator (SHA) can be used in explosion-proof applications. Sensors are upgraded, and explosion proof motors are used in these cases.

Position measurement can be as simple as end-of-travel limit switches however, generally the SMART electro-hydraulic actuator (SHA) is used in configurations that incorporate an absolute position sensor that is mounted either outside the cylinder, or internally using magnetostrictve technology.

Standard position sensors used on the SMART electro-hydraulic actuator (SHA) provide up to +/- 0.001” accuracy.

For most applications, force is measured using a pressure transducer on either (or both) the extend side and retract side of the actuator. The pressure transducer is mounted in the fluid path that supplies pressure to either side of the piston. Force is calculated using πr² X the pressure of the system in PSI. With the SHA, using the pressure sensor is a very cost-effective way to accurately measure force as opposed to using expensive loadcells.

The pressure transducers used for force measurement are rated at 1% of full scale. The typical sensor used is rated at 3000PSI at 10V. For finer resolution, multiple sensors could be incorporated to switch between sensors as needed.

Yes. The SMART electro-hydraulic actuator (SHA) offers an internal position sensor that is mounted to the rear of the actuator and extends into the cylinder rod which is gun-drilled to accommodate the sensor probe. This sensor uses magnetostrictive technology. Internal sensors are typically used in applications where an external sensor would be subject to damage or contamination. Internal sensors can be used with cylinder rods 1 in or greater diameter.

Both the external and internal type of position sensor used on the SMART electro-hydraulic actuator (SHA) is magnetostrictive technology which is a form of non-contact measurement that is very precise and reliable.

The SMART electro-hydraulic actuator (SHA) uses a minimal amount of fluid. For example, a cylinder that produces 10,000 Lbs. of force with an 8” stroke only requires 14 oz of fluid, often less than the lubrication in a mechanical gearbox. The enclosed system used in the SHA eliminates the extensive maintenance required by traditional HPUs with hydraulic cylinders.

One of the unique advantages of the SMART electro-hydraulic actuator (SHA) is the multitude of configurations that are available. This benefits users because the SHA is better able to fit the available space envelope for more applications. This flexibility is due to the SHA using fluid to provide motion rather than using gears, drive screws and driven nuts that limit configuration flexibility. SHA configurations include parallel, in-line, right-angle and many others.

The SMART electro-hydraulic actuator (SHA) has many mounting and attachment options available. These options are for both the rod-end and actuator itself that accommodate most applications. You can find more details on the extensive number of SHA mounting options.

The SMART electro-hydraulic actuator (SHA) can be provided as an “actuator only” option to be used with the preferred motor of choice. The actuator only option is used when the motor and drive are provided by others. With this approach, Kyntronics provides the actuator with the motor mounting bracket and shaft coupling for the specific motor chosen to be used. Common motors used are Rockwell Automation/Allen Bradley, Siemens, Mitsubishi, and several others.

Kyntronics sizes the motor & drives as needed for the application when using our All-in-One solution. For Rockwell Automation customers, we provide the torque and speed required. Kyntronics is familiar with the Rockwell Automation motion analyzer and can assist when needed.

No. The SMART electro-hydraulic actuator (SHA) incorporates a hydraulic lock using check valves that hold the actuator in position when the motor stops. This locking mechanism also applies if power is lost to the SHA. Kyntronics also offers a solenoid lock option that provides additional functionality required by some applications.

Yes, food grade fluid is available upon request.

In those cases where the available space envelope will not allow the SMART electro-hydraulic actuator (SHA) to fit, Kyntronics offers a Servo Power Unit (SPU) product that incorporates all of the design characteristics of the SHA power unit while interfacing to a customer-supplied cylinder through hoses or pipe connections. The SPU includes the pump, manifold, valves, motor, servo drive/control and cabling and comes with quick connectors for attaching the hoses to the cylinder.

Yes, the SMART electro-hydraulic actuator (SHA) includes two pressure relief valves (one for extend and one for retract) that are standard on every actuator. This helps protect the actuator and the machine.

The maximum operating pressure of the SMART electro-hydraulic actuator (SHA) is 3,000 PSI. During the application engineering process, we will determine the typical operating pressure required by the application and factory-adjust the pressure relief valves accordingly.

SMART electro-hydraulic actuator (SHA) efficiency (mechanical power out vs. electrical power in) is approximately 70 – 80%. Compared with traditional hydraulics and screw-type actuators, the SHA is the highest efficiency actuator available and in many instances (based on internal testing), the SHA is up to 50% more efficient than screw-type actuators. This is because the SHA design locates the power transmission source (pump) very near the cylinder and there are no metal-to-metal contact points (all components ride on fluid). Several factors adversely impact efficiency in traditional hydraulics including constantly running HPUs with inefficient motors, losses in hoses, fittings, valves and other components that connect the HPU to the cylinders and many other conditions. The primary factors that impact screw-type actuator efficiency is the friction associated with metal-to-metal contact points including gears, screws, nuts, etc. For more information: https://www.ifpe.com/news/assessing-industrial-hydraulic-system-efficiency

The closed-cell foam used in the SMART electro-hydraulic actuator (SHA) allows for compensation of the fluid displaced by the volume of the cylinder rod. For example, when the rod is retracted, the extra fluid (compared to when the rod is extended) must be accommodated somehow since the SHA does not incorporate a separate accumulator. The extra fluid flows into the chamber where the closed-cell foam is located which compresses slightly to accommodate the fluid. When the actuator rod is extended, the foam returns to its normal condition. The amount of pressure in the foam chamber is less than 30PSI. The actuator is always under minimal pressure and it is important not to remove any components from the actuator or fluid could escape reducing the internal pressure that is required for the SHA to properly operate.

The motor on the SMART electro-hydraulic actuator (SHA) is used bi-directionally. One direction to extend the rod and the opposite direction to retract the rod.

There are several features of the SMART electro-hydraulic actuator (SHA) designed to remove heat. Dual fans are used in conjunction with an efficient heat sink attached to the pump where the majority of the heat is generated. In addition, aluminum extrusions containing the reservoir foam conduct heat from the fluid. Finally, a temperature sensor attached to the pump with a connection to the control provides over-temperature protection. Kyntronics works with our customers to determine the optimal configuration of the SHA taking into account the force, speed and duty cycle of the application to minimize heat.

No. Due to the design of the SMART electro-hydraulic actuator (SHA) incorporating an integral hydraulic cylinder, the SHA is very robust when exposed to shock loads due to the shock-absorbing characteristics of hydraulics. Screw-type electro-mechanical actuators (EMA) incorporate gears, nuts, screws and other mechanical components that when exposed to shock loads, can fracture or have premature failure from these types of loading conditions.

The SMART electro-hydraulic actuator (SHA) incorporates a hydraulic lock using check valves that hold the actuator in position when the motor stops. This locking mechanism also applies if power is lost to the SHA. Kyntronics also offers a fail-safe solenoid lock option that provides additional functionality required by some applications.

The SMART electro-hydraulic actuator (SHA) is a closed and sealed system that does not require the hydraulic fluid to be changed. Unlike screw-type actuators, the SHA does not require periodic lubrication. The only scheduled maintenance is for a rod seal replacement around 50,000,000 inches of travel, similar to most cylinders. The threaded design of the rod seal components allows replacement in the field using a factory supplied seal kit. Periodic inspection of cabling, sensors and other peripheral components for wear or damage is of course a general best practice that is also recommended as would be performed on any type of equipment or machinery. If fans are installed, it is also recommended to monitor any debris that may block proper airflow use shop air to blow out any contamination

The SMART electro-hydraulic actuator (SHA) is a closed and sealed system that does not require the hydraulic fluid to be changed.

The SMART electro-hydraulic actuator (SHA) is a very robust solution. However, like any robust solution, it is important to properly install and utilize recommended programming techniques to prevent the SHA from continually running beyond stop limits and possibly damaging the unit. Kyntronics provides guidance and best practices for proper programming as part of our applications and commissioning assistance.