Servohydraulic Components

The final element in our dynamic testing product portfolio is the manufacture of all the necessary accessories such as hydraulic power packs, servohydraulic testing actuators, or hydraulic distribution units. Our portfolio is constantly being expanded through a program of continuous development and inclusion of new products, allowing us to satisfy our customer’s most demanding quality requirements while continually improving the quality of our products.
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For determination of durability ZwickRoell can provide a customized modular system to cover all testing requirements, comprising actuators, hydraulic power packs, distribution units, servohydraulic testing machines and other accessories.

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Hydraulic Power Packs

HP series hydraulic power packs were specially developed to fulfill the demanding requirements of servohydraulic testing machines and testing systems. They feature demand-dependent flow-rate control, with delivery at a constant pressure of 280 or 210 bar.

Description of Operation of Hydraulic Power Packs

ZwickRoell Series HP power packs deliver high operational reliability combined with long service life, with all components mounted on top of the oil tank for easy access.
The self-priming radial-piston pump is driven by an asynchronous motor. The nine pistons are in hydrostatically balanced contact with the stroke ring. Flow rate is regulated by the stroke-ring eccentricity, which is adjusted via two control pistons located opposite each other. The pressurized oil is routed via a high-pressure filter and is then available to the appliance at output ‘P’. A factory-set pressure relief valve prevents excessive increases in pressure.

The return oil is routed to the rear part of the tank via an oil-water heat-exchanger and a return oil filter. A temperature-controlled valve switches the coolant water flow on and off. To prevent cavitation a degassing filter is located in the tank, while an oil mist filter cleans air vented from the tank.

Advantages and features of hydraulic power packs 

  • The variable-capacity pump features automatic adjustment, consuming only sufficient electrical power to maintain the required flow at any given moment.
  • The 9-piston pump delivers oil flow with minimal pressure fluctuations.
  • The power packs have multiple vibration isolation.
  • All connections, including pressure filter, feature operator-friendly front mounting.
  • An integrated oil collection pan catches minor drips and leakages during hose and filter changes.
  • Modern power pack control with PLC for convenient operation, including monitoring and status display.
  • A wide range of monitoring functions are available, including oil pressure, oil level, oil temperature, filter.
  • The power pack can be operated either directly from the electrical cabinet or from the test stand via remote control (optional).
  • The power packs are supplied ready for fitting of an acoustic hood. These can also be retrofitted.
  • A vibration stabilizer can be retrofitted in order to dampen disruptive vibrations in pipework installations where necessary.
  • The servohydraulic testing actuators are connected by a set of hoses. Piping is recommended where longer runs are involved. Power packs can also be coupled together for use with large hydraulic installations.

Technical overview 20 l/min

System pressure

210

280

bar

Item No.

068877

058726

Nominal flow-rate

20

20

l/min

Oil temperature range

40…60

40…60

°C

High-pressure filter to ISO 16889, absolute

3

3

µm

Oil reservoir max. volume

235

235

l

Noise level (distance approx. 1 meter)

75

75

dB(A)

Motor output at nominal flow rate

8.5

11

kW

Electrical supply[1]

400, 3 PH/N/PE, 50 Hz

400, 3 PH/N/PE, 50 Hz

V

Wire cross-section (up to 35m cable length)

4 x 4

4 x 10

mm²

Fuse protection provision by customer

20

40

A

Protection class

IP 55

IP 55

Weight (including oil)

900

900

kg

Hydraulic connections for:

P (high pressure)

G 3/4"

G 3/4"

BSP P

R (return flow)

G 1"

G 1"

BSP P

L (leak oil)

G 1"

G 1"

BSP P

Radiated heat loss

1.2

1.6

kW

Coolant water req. at 25°C

15

20

l/min

Coolant water supply connection (inlet/outlet)

G 3/4" / G 3/4"

G 3/4" / G 3/4"

Oil types

HLP-46 or HVLP-46

HLP-46 or HVLP-46; suggest Mobil DTE 25

  1. Alternative supply voltages and frequencies (60 Hz) available on request

Technical overview 40 l/min

System pressure

210

280

bar

Item No.

068878

063427

Nominal flow-rate

40

40

l/min

Oil temperature range

40…60

40…60

°C

High-pressure filter to ISO 16889, absolute

3

3

µm

Oil reservoir max. volume

235

235

l

Noise level (distance approx. 1 meter)

75

75

dB(A)

Motor output at nominal flow rate

16.25

22

kW

Electrical supply[1]

400, 3 PH/N/PE, 50 Hz

400, 3 PH/N/PE, 50 Hz

V

Wire cross-section (up to 35m cable length)

4 x 16

4 x 25

mm²

Fuse protection provision by customer

63

80

A

Protection class

IP 55

IP 55

Weight (including oil)

900

900

kg

Hydraulic connections for:

P (high pressure)

G 3/4"

G 3/4"

BSP P

R (return flow)

G 1"

G 1"

BSP P

L (leak oil)

G 1/2"

G 1/2"

BSP P

Radiated heat loss

2.4

3.3

kW

Coolant water req. at 25°C

30

40

l/min

Coolant water supply connection (inlet/outlet)

G 3/4" / G 3/4"

G 3/4" / G 3/4"

Oil types

HLP-46 or HVLP-46

HLP-46 or HVLP-46; suggest Mobil DTE 25

  1. Alternative supply voltages and frequencies (60 Hz) available on request

Technical overview 80 l/min

System pressure

210

280

bar

Item No.

068880

038136

Nominal flow-rate

80

80

l/min

Oil temperature range

40…60

40…60

°C

High-pressure filter to ISO 16889, absolute

3

3

µm

Oil reservoir max. volume

620

620

l

Noise level (distance approx. 1 meter)

81

81

dB(A)

Motor output at nominal flow rate

33.25

46.5

kW

Electrical supply[1]

400, 3PH/N/PE, 50 Hz

400, 3PH/N/PE, 50 Hz

V

Wire cross-section (up to 35m cable length)

4 x 35

4 x 50

mm²

Fuse protection provision by customer

100

125

A

Protection class

IP 55

IP 55

Weight (including oil)

1950

1950

kg

Hydraulic connections for:

P (high pressure)

G 1"

G 1"

BSP P

R (return flow)

G 1 1/4"

G 1 1/4"

BSP P

L (leak oil)

G 1"

G1"

BSP P

Radiated heat loss

4.5

6

kW

Coolant water req. at 25°C

52

75

l/min

Coolant water supply connection (inlet/outlet)

G 1" / G 1"

G 1" / G 1"

Oil types

HLP-46 or HVLP-46

HLP-46 or HVLP-46; suggest Mobil DTE 25

  1. Alternative supply voltages and frequencies (60 Hz) available on request

Technical overview 170 l/min

System pressure

210

280

bar

Item No.

068882

029981

Nominal flow-rate

170

170

l/min

Oil temperature range

40…60

40…60

°C

High-pressure filter to ISO 16889, absolute

3

3

µm

Oil reservoir max. volume

1240

1240

l

Noise level (distance approx. 1 meter)

82

82

dB(A)

Motor output at nominal flow rate

73

95.5

kW

Electrical supply[1]

400, 3PH/N/PE, 50 Hz

400, 3PH/N/PE, 50 Hz

V

Wire cross-section (up to 35m cable length)

4 x 70

4 x 95

mm²

Fuse protection provision by customer

160

200

A

Protection class

IP 55

IP 55

Weight (including oil)

3150

3150

kg

Hydraulic connections for:

P (high pressure)

G 1 1/4"

G 1 1/4"

BSP P

R (return flow)

G 1 1/2"

G 1 1/2"

BSP P

L (leak oil)

G 1"

G 1"

BSP P

Radiated heat loss

8.4

11

kW

Coolant water req. at 25°C

90

120

l/min

Coolant water supply connection (inlet/outlet)

G 1 1/2" / G 1 1/2"

G 1 1/2" / G 1 1/2"

Oil types

HLP-46 or HVLP-46

HLP-46 or HVLP-46; suggest Mobil DTE 25

  1. Alternative supply voltages and frequencies (60 Hz) available on request

Technical overview 270 l/min

System pressure

210

280

bar

Item No.

055654

035423

Nominal flow-rate

270

270

l/min

Oil temperature range

40…60

40…60

°C

High-pressure filter to ISO 16889, absolute

3

3

µm

Oil reservoir max. volume

1300

1300

l

Noise level (distance approx. 1 meter)

88

88

dB(A)

Motor output at nominal flow rate

125.5

165.5

kW

Electrical supply[1]

400, 3PH/N/PE, 50 Hz

400, 3PH/N/PE, 50 Hz

V

Wire cross-section (up to 35m cable length)

2x (4 x 70)

2x (4 x 95)

mm²

Fuse protection provision by customer

250

320

A

Protection class

IP 55

IP 55

Weight (including oil)

3850

3850

kg

Hydraulic connections for:

P (high pressure)

SAE 2" 6000 psi

SAE 2" 6000 psi

BPS P

R (return flow)

G 2"

G 2"

BSP P

L (leak oil)

G 1"

G 1"

BSP P

Radiated heat loss

12.5

16.5

kW

Coolant water req. at 25°C

150

200

l/min

Coolant water supply connection (inlet/outlet)

G 1 1/2" / G 1 1/2"

G 1 1/2" / G 1 1/2"

Oil types

HLP-46 or HVLP-46

HLP-46 or HVLP-46

  1. Alternative supply voltages and frequencies (60 Hz) available on request

Downloads

Servohydraulic Testing Actuator

ZwickRoell's servohydraulic testing actuators feature sturdy, robust construction and are used both in servohydraulic testing machines and as single testing actuators, for example on a clamping plate. When used in conjunction with a servo valve they enable complex loading sequences to be implemented with great accuracy. 

Advantages & features of servohydraulic testing actuators

  • The servohydraulic cylinders are available in various versions with test loads from 5 to 2500 kN.
  • The standard testing actuator stroke is 50, 100, 150, 250 or 400 mm.
  • They are designed for system pressure of 210 or 280 bar.
  • The servohydraulic testing actuators are double-rod-cylinder with equal piston surface area for tension and compression.
  • The hydrostatic piston-rod bearings guarantee quasi-frictionless operation and high transverse force absorption.
  • Hydraulic end-cushioning allows high piston speeds.
  • The servohydraulic actuator is fitted with an integrated displacement transducer.
  • They can be top- or bottom-mounted.

Technical overview of servohydraulic testing actuators 10 to 50 kN

Nominal force
[kN]

Stroke
[mm]

Valve block
[l/min]

No. of
servo valves

Piston
rods Ø

Connection size[1]

±10

50

65

1

45

Ø70,6 x M8 and 6x Ø 9
Centering spigot Ø 30 H7

±10

50

130

2[2]

45

±10

100

65

1

45

±10

100

130

2[2]

45

±10

150

65

1

45

±10

150

130

2[2]

45

±10

250

65

1

45

±10

250

130

2[2]

45

±25

50

65

1

45

±25

50

130

2[2]

45

±25

100

65

1

45

±25

100

130

2[2]

45

±25

150

65

1

45

±25

150

130

2[2]

45

±25

250

65

1

45

±25

250

130

2[2]

45



±50

50

65

1

45

Ø 105,12 x M10
and 12 x Ø 11
Centering spigot Ø 70 H7

±50

50

130

2[2]

45

±50

100

65

1

45

±50

100

130

2[2]

45

±50

150

65

1

45

±50

150

130

2[2]

45

±50

250

65

1

45

±50

250

130

2[2]

45

  1. The piston rod is provided with a connecting flange
  1. Valve block for 2 valves required, Item No. 924802

Technical overview of servohydraulic testing actuators 100 to 1000 kN

Nominal force
[kN]

Stroke
[mm]

Valve block
[l/min]

No. of
servo valves

Piston
rods Ø

Connection size[1]

±100

50

65

1

80

Ø105, 12 x M10
and 12x Ø 11
Centering spigot Ø 70 H7

±100

50

250

4[2]

80

±100

100

65

1

80

±100

100

250

4[2]

80

±100

150

65

1

80

±100

150

250

4[2]

80

±100

250

65

1

80

±100

250

250

4[2]

80

±100

400

65

1

80

±100

400

250

4[2]

80

±250

100

65

1

125

Ø165, 12 x M16
and 12 x Ø 17.5
Centering spigot Ø 100 H7

±250

100

250

4[2]

125

±250

150

65

1

125

±250

150

250

4[2]

125

±250

250

65

1

125

±250

250

250

4[2]

125

±250

400

65

1

125

±250

400

250

4[2]

125

±500

100

65

1

160

Ø 240, 12 x M20
and 12 x Ø 17.5
Centering spigot Ø 100 H7

±500

100

250

4[2]

160

±500

150

65

1

160

±500

150

250

4[2]

160

±500

250

65

1

160

±500

250

250

4[2]

160

±500

400

65

1

160

±500

400

250

4[2]

160

±1000

100

250

4[2]

200

Ø 280, 12 x M24
and 12 x Ø 26
Centering spigot Ø 100 H7

±1000

100

1000[3]

1

200

±1000

250

250

4[2]

200

±1000

250

1000[3]

1

200

±1000

400

250

4[2]

200

±1000

400

1000[3]

1

200

  1. The piston rod is provided with a connecting flange
  1. Requires valve block either for 2 valves (Item No. 924802) or for 4 valves (Item No. 032955)
  1. Suitable for Moog 3-stage servo valve Type 792

Actuators with a nominal force greater than 1000 kN are available on application.

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Hydraulic Distribution Unit

The hydraulic distribution unit is the electrically operated switching device in servohydraulic testing machines. It connects or disconnects the hydraulic pressure for a servohydraulic testing actuator or servohydraulic testing machine. A connecting valve is allocated to each consumer, allowing them to be switched independently of each other. The modular design enables addition of an extra switching manifold whenever required.

Advantages & features of the hydraulic distribution unit

There are three different switching states:

  • OFF: Both pressure lines and return oil lines are disconnected from the hydraulic oil supply.
  • LOW PRESSURE: The connected single testing actuator is in setting mode with reduced pressure and reduced flow.
  • HIGH PRESSURE: The servohydraulic testing actuator is in test mode. Full hydraulic power is available.

The smooth, controlled change from low to high pressure avoids pressure surges. In the event of a sudden fall in pressure, for example due to a fractured hose, the hydraulic supply is automatically switched off.

The hydraulic distribution units can be used in networks operating at both 210 bar and 280 bar. The switching manifolds are available for flow rates from 65 l/min to 500 l/min; special versions are also available for higher rates.

Technical overview of distribution unit

Distribution columns/nominal flow[1]

250

250

500

500

500

l/min

Max. number of switching manifolds[1]

4

2

8

4

2

Nominal flow-rate of switching manifold

65

125

65

125

250

l/min

System pressure

210 to 280

210 to 280

210 to 280

210 to 280

210 to 280

bar

Low pressure-rate and flow-rate monitoring

pressure range

1 to 10

1 to 10

1 to 10

1 to 10

1 to 10

bar

flow range

2 to 25

2 to 25

2 to 25

2 to 25

2 to 25

l/min

Control voltage

24

24

24

24

24

V DC

Power consumption, max.

2.6

2.6

2.6

2.6

2.6

A DC

Hose connections (distribution columns):

P (high pressure) – 1x

G 1½

G 1½

G 2

G 2

G 2

BSP P

R (return oil) - 1x

G 1½

G 1½

G 2

G 2

G 2

BSP P

L (leakage oil) - 1x

G ¾'

G ¾'

G ¾'

G ¾'

G ¾'

BSP P

Hose connections (switching manifold):

P (high pressure) – 1x

G ¾'

G 1

G ¾'

G 1

G 1½

BSP P

R (return oil) - 1x

G ¾'

G 1

G ¾'

G 1

G 1½

BSP P

L (leakage oil) - 1x

G 1½

G 1½

G 1½

G 1½

G 1½

BSP P

  1. An order item comprises the distribution column plus the required number of switching manifolds.

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