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CATA

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ASSEMBLY AND TEST BANCHESFOR HYDRAULIC CYLINDERS

Innovation and Quality

Constant Research in product and solutions

Since 2000 we have been designing custom machines, for the industrial automation fi eld. Needs and philosophies, each time very specifi c and diff erent: all to be thought, projected, created new.

Thanks to the experience that was gradually growing and being reinforced, with the trust placed on us by our customers from the manufacturers sector, we came to produce in 2005 for the fi rst time, as a special commitment, a machine for the testing of hydraulic cylinders.

I realized soon that it was a complex, strategic, innovative, concept. It was going to change within the company the philosophy of production and quality control of the product.

The hydraulic cylinder, a fundamental element in mobile machinery: which requires an accurate method of processing, cleaning and assembly, deserves also an adequate tool for final verifi cation and proof before it is delivered to the fi nal customer.

The synergy between our departments: electrical, mechanical and software was a fundamental leverage for project development and implementat ion of the hydraul ic systems which we are presenting You here.

The result over time has led to the completion of an advanced equipment, perfect for manufacturers and repairers of hydraulic cylinders; who want to keep up with the times, in this peculiar historical and economic period.

I proudly present to you our range of BAT-H equipment.

Intelligent Automation, providing service to the Human Talent.

Alberto Frittoli CEO

past, present, future

Evolution in Automation

Time ago, when there were no or less automated systems, the cylinders were assembled and disassembled by hands, with great energy expenditure and by employing long time and complex procedures. Particular attention must also be paid to safety of the operator nowadays: many are risks of accidents, and heavy loads are a danger.

Today A.F. Automazione, off ers a solution to reduce drastically the accidents, working-times and by optimizing productivity. More and more companies today use wisely to certify the quality of their cylinders; the testing phase is to be considered an “active” part of the production process itself.

This is a very important phase that must be performed with care and competence to guarantee only the top quality of cylinders to your customer.

Our group has set itself the goal of improving the working environment in mechanical workshops and increasing safety standards for operators.

Our test benches have unique characteristics as every machine is a customized project: thanks to the synergy between our departments, we develop solutions by identifying the specifi c needs of each customer: providing expertise from the delivery of the custom designed product to its installation, training and assistance.

Detailed Test Reports prove the conformity of the cylinder to the company’s required quality standards.

In the following future, more and more companies will look for effi ciency, safe and automated production systems.

A.F. Automazione strives for being a leader in this strategic fi eld of business, the mechanical industrial sector is already in change globally speaking.

We’re ready, and You?

Synergy and simplicity”Synergy is the interaction or cooperation of more agents able to produce a combined effect greater than the sum of their separate effects “

With this concept imprinted in our mind, A.F. Automazione projects custom designed machines, applies own software and mounts all the hardware, to keep all our efforts and talent aligned in perfect control.

The experience meets innovative and future-oriented techniques.

The AF15.02 and AF35.02 software are both result of a study that lasted for years, and is still in evolution: as it has the goal to integrate new mechanics and the user friendly interface technology.

Our mission is embodied by the following thought:

“We develop intelligent automation systems, at the service of human talent”.

Software “The customized software AF 15.02 and AF35.02 are the flagship of a study that lasted for years, and which is in continuous evolution, integrating mechanics and software design.”

Hardware“The test bench for hydraulic cylinders is our best project realized after years of experience in the industrial automation field. “

N°Inspector

Batch n° Pieces n°

AF/001 10

Bore : Stem :

100 mm 60 mm

Notes:

AF Automazione - Via G. Oldoini 10, 26100 Cremona (Italy) - VAT IT00455590190 - www.afautomazione.it

Stroke Chart

Cylinder nr.2 AF001.02

Machine Characteristic:

Test bench for hydraulic cylindersStroke :

800 mm

2015/04Date Internal job n°

Name XYZ

Cylinder Test Report

Denomination Design n°

2015-04-05 15.22.59

Customer Customer Order n°

Company XYZ Apr-15

0

50

100

150

200

250

0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000

mm

ms

Measure

N°Inspector


AF/001 10

Bore : Stem :

100 mm 60 mm

Operating Pressure 135 barTesting Pressure

202 bar

40,1 °C

Positive Negative

Notes:


Stroke :

Internal job n°

2015-04-05 15.22.59

Characteristic:

Denomination

AF001.02

Machine

Pressure Test

Test bench for hydraulic cylinders

Design n°

Cylinder nr.2

Oil Temperature at the end (°C)

Proof mean

800 mm

f) No oil leakage from weld joint

Cylinder Test Report

Customer

Apr-15

Customer Order n°

Company XYZ

Date

Name XYZ

2015/04

e) No oil leakage from rod seals

ResultNotes

Test of DimensionsVisual or intrumental test

Class of Contamination 18 / 16 / 13

h) Test of piston seals (if requested from customer)

1) dimensions of cylinder, rod out

2) dimensions of cylinder, rod in

Low Pressure Test500 kPa (5 bar) > 32 mm > 1000 kPa (10 bar)a) Vibration or locking during motion

b) measure of total stroke

UNI EN 10100:2005

c) No oil leakage from rod seals

g) Check of the functionality of the end-stroke cushioning

d) No oil leakage from static seals

e) No oil leakage from adjustment screws

a) check of structural integrity of the cylinder

High Pressure Test1.5 * working pressure

b) No oil leakage from static seals

c) No oil leakage from adjustment screws

d) No oil leakage from weld joint

N°Inspector


AF/001 10

Bore : Stem :

100 mm 60 mm

General DataOil temperature at the beginning of the test (°C)

Oil temperature at the end of the test (°C)

Cleanliness test with compressed airNumber of execution

Low pressureMin pressure during rod going out

Min pressure during rod going in

FlushingNumber of execution

Measured pressure (bar)

Max flow-rate (lt/min)

Measured stroke (mm)

High pressure testMax supplied flow-rate (f) (lit/min)

Flow-rate during compression (forward) (lt/min)

Pressure during compression (forward) (bar)

Time of Compression (forward) (sec)

Pressure at leakage test start (forward) (bar)

Pressure at leakage test end (forward) (bar)

Duration of leakage test (forward) (sec)

Max supplied flow-rate (backward) (lit/min)

Flow-rate during compression (backward) (lt/min)

Pressure during compression (backward) (bar)

Time of Compressione (backward) (sec)

Pressure at leakage test start (backward) (bar)

Pressure at leakage test end (backward) (bar)

Duration of leakage test (backward) (sec)

Emptying with AirNumber of executions

Notes:


Customer Customer Order n°

Company XYZ Apr-15

3

14,1

Denomination Design n°

Cylinder nr.2 AF001.02

Machine Characteristic:

Test bench for hydraulic cylindersStroke :

800 mm

Cylinder Test Report 2015/04Date Internal job n°

Name XYZ 2015-04-05 15.22.59

Test Results

38,540,1

219,73

55

554,337

210,5

201,4

209,5

61,8

10

2

1061,814,1

209,95

208,7

202,2

5

The test report is the document that certifi es quality and performance of the cylinder.

Through our software machine it is possible to perform the following tests:

Air test;

Flushing;

Low pressure test;

High pressure test;

Stress test;

At equivalent chambers pressure-test.

The results of the tests mentioned above are documented by a fi nal report which can be saved and shared in digital or paper printed. The test report can be archived, customized to what is concerning the information detained important, printed or sent in digital to your customer.

Test Report

Your Headline The header of the test report is personalized with your logo and information of relevant interest for your company or production.

Your QR Code Generate your QR code with the information you want to recall by scanning it; for example: data on the cylinder tested, specifi c layouts or website links to fi nd immediately urgent info.

the heart of the machine

The Hydraulic Power Unit

The hydraulic power unit is the starting point of an already very advanced test-station; It allows the cylinders to be tested in order to certify their quality and performance.

The HPU (Hydraulic Power Unit) can be in future easily integrated with other equipment: such as the support bench, assembly group, and other optional devices in order to achieve higher production standards, and almost zeroing the number of returns for non-compliance of product.

The hydraulic power unit is equipped with an industrial PC and the software for cylinder testing. The HPU is extremely useful by itself, stand alone.

Your testing machine can be customized with maximum pressures applied up to 350/500/700 bar.

The tests that can be performed by the HPU are the following:

• Air test

• Flushing

• Low pressure test

• High pressure test

• Pressure test of equivalent chambers

• Stress test

Certify the quality of your production because it is the winning choice to be competitive in the today’s market.

Power with control, heart in synchrony with the mind.

HPU-15 “Information Sharing between the machine and Company IT systems of the results obtained out of the testing phase. Real-time assistance in the event of anomalies or alarms.”

HPU-35“ We opt for only the top quality of the hydraulic and electronic components to build our machines.Hawe, Parker, Siemens, MP Filters are some of thetop brands we trust.“

The BAT-H 15 bench is a system designed mainly for testing of hydraulic cylinders of small and medium size. Diff erent models of test-bench respond to different management of your workshop or production philosophy.

The following items and components are provided as a standard, on every test bench available:

• Hydraulic Power Unit, with control panel and electrical panel.

• Standard pressures up to 350 bar (available higher pressures on request).

• Mechanical structure in carbon steel and aluminium electro-extrusions.

• Pneumatic clamps for cylinder locking in place.

• Rear stop wall, for cylinder blocking during rod-introduction phase.

• Transparent resistant shatterproof cage as to ensure safety while tests are carried out.

SERIES

BAT-H 15

SUITABLE CYLINDERS MIN MAX

Length (mm) 300 1500External Ø (mm) 35 250Flange Ø (mm) - 370Max weight (kg) - 600

*indicative values, which will be defi ned in the fi nal off er phase.

BASIC TESTING

Simplifi ed test bench combining the basic functions

of this series with a lower investment Suitable for

companies with occasional testing needs.

Maximum dimensions 1500mmx1500mm h2000mm,

Worktop Height 900mm,

Weight of the machine 2000kg *

BAT-H 15 BASIC

BAT-H 15 TWIN

BAT-H 15 COMPLETE

BAT-H 15

SINGLE TESTING STATION FOR SMALL CYLINDERS

Suitable for testing cylinders of small and medium

dimension, up to a maximum of 2.000mm of length,

with an external diameter up to 300mm.

Max dimensions 1500mmx1500mm h2000 mm,


Weight of e machine 1000kg *

ASSEMBLY AND TESTING

Assembly unit complete with the Screw Unscrewing

section for the heads of cylinders.

Maximum dimensions 4500mmx1500mm h2000mm,



INTESIVE OR SERIAL TESTING

Double testing station for cylinders of small and medium

size.

Overall dimensions 3800mmx1500mm h2000mm,



z

BAT-H 35-4

BAT-H 35-7 ASSEMBLY AND TESTING

Suitable for assembling and testing hydraulic cylinders with

external Ø up to 700mm. Could be completed with the head

screw-unscrewing assembly section.


Worktop height 900mm,

Weight of the machine 4300kg.*

BAT-H 35-10 ASSEMBLY AND TESTING

Suitable for assembling and testing hydraulic

cylinders with external Ø up to 1000mm.




BAT-H 35-HYBRID ASSEMBLY AND TESTING

Hybrid version for broader range of cylinders, from very

small, to marked or important lengths. It could be completed

with Screw-unscrewing and tightening group for heads.



Weight of the machine 1000kg*

ASSEMBLY AND TESTING

Suitable for assembling and testing hydraulic cylinders with

external Ø up to 400mm. This model can be completed

with the Screw-unscrewing and tightening group for heads.

Overall dimensions 7400mmx6250mm h2000 mm,


Weight of the machine 3500kg.*

The series of machines here considered are mainly built with the purpose of assembling hydraulic cylinders of medium and great dimensions, as heavy weights.

These range of cylinders may result diffi cult or impossible to be managed in manual mode and a safe manner by one or even more operators. Testing module has always been applied on these machines, until now.

On all the models of the series Bat-h 35, the following functions or component are present as a standard:

•Separate hydraulic power unit, with control pc unit, and electric panel.

•Standard pressures up to 350 bar (available higher pressures on request).

•Reinforced mechanical structure to support the higher loads in terms of cylinders positioned.

• Hydraulic clamps for cylinder blocking.

•Rear stop wall for cylinder blocking in the rod-introduction phase.

•Sliding protection, of 8mm thickness,transparent as shatterproof proper cage to ensure safety during testing phase.

SERIES BAT-H 35

SUITABLE CYLINDERS MIN MAX

Length (mm) 600 3500External Ø (mm) 80 700Flange Ø (mm) - 1000Max weight (kg) 6000 12000

*indicative values, which will be defi ned in the fi nal off er phase.

Ref: 6800.00 Ref: 6800.00 Ref: 6800.00

Ref: 6800.00 Ref: 6800.00 Ref: 6800.00

Measurement Laser,for rod stroke control

A laser measurement system for check the stroke of the rod and its exit and return speeds (bwd-fwd).

Efficiency control of internal position transducers.

An electronic system (output in Volts and Ampere), to verify the electrical efficiency of the position transducers installed inside the cylinder.

Horizontal locking with chains on worktop.

Locking device for assembly and testing of cylinders when positioned on worktop, suggested for great dimensioned cylinders.

PRICE ON REQUEST PRICE ON REQUEST PRICE ON REQUEST

ICM – Inline Contamination Monitor

Measures automatically the level of particles contamination, humidity and temperature of the oil used during the test phase.

PRICE ON REQUEST

2020 OPTIONALIt is possible to integrate on your test and / or as-sembly bench dedicated and specific accessories as to meet specific requirements by customizing your ma-chine.

To get the best possible performance from the ma-chine, it is essential to find the right equipment and devices that lead most effectively to a specific goal in production and in testing.

Choose to optimize the tempos and improve the quality of the product delivered to Your customers.

“Let your test-assembly bench perform at its finest possibilities”

*** Possibility to upgrade modules on all benches model described, with pressure higher than 350 bar:

500 bar in Manual or Automatic

700 bar in Manual or Automatic.

optional

ON ALL THE BAT-H MODELS

» Guarantees that the tests are carried out with oil in the best conditions.

» Guarantees that the system of filtration is efficient.

» Respect of the regulations ISO4406 and NAS1638.

» The values are shown on the display of the device, registered and printed in the test report.

» The data collected is stored and entered in the test report document.

» The software allows you to check the actual braking curve for brake cylinders.

» The curve is drawn in a graph and compared with reference sample curves.

» The signal sent by the internal transducer is acquired by our software.

» The signal is compared with the specific travel values of the cylinder

» For cylinders with external Ø over 300 mm.

» Chain system tensioned by two hydraulic cylinders to ensure the position and keep in place.

» The locking “V shaped” supports system are positioned at the two extremities of the cylinder being tested on the bench and the chain runs above.

Ref: 6800.00 Ref: 6800.00 Ref: 6800.00 Ref: 6800.00

Screwing and Unscrewing System for the cylinder head.

Innovative system to perform the automatic screwing and un-screwing of the cylinder head.The system hooks the rod and screws it into the barrel.

PRICE ON REQUEST

Shuttle / Introducer cart (on rod side).

By entering the geometric data concerning the cylinder, the system automatically positions the piston aligning it to the barrel, and ensuring perfect introduction.

Vertical assembly and testing of cylinders.

Locking device for cylinder assembly and testing in vertical position.

Predisposition for a Contrast Cylinder in opposed force.

Customized system for carrying out leakage tests on non-return valves (check-valves) installed on hydraulic cylinders.

PRICE ON REQUEST PRICE ON REQUEST PRICE ON REQUEST

optional

ON ALL THE BAT-H MODELS

2020 OPTIONALIt is possible to integrate on your test and / or as-sembly bench dedicated and specifi c accessories as to meet specifi c requirements by customizing your ma-chine.

To get the best possible performance from the ma-chine, it is essential to fi nd the right equipment and devices that lead most eff ectively to a specifi c goal in production and in testing.

Choose to optimize the tempos and improve the quality of the product delivered to Your customers.

“Let your test-assembly bench perform at its fi nest possibilities”

*** Possibility to upgrade modules on all benches model described, with pressure higher than 350 bar:

500 bar in Manual or Automatic

700 bar in Manual or Automatic.

» Rotating group, motorized in both directions.

» Automatic coupling and rotation system of the flange.

» Automatic height adjustment for centering execution (rod/barrel).

» Parameters that can be set by PC and stored according to the different types of cylinders.

By remote control, the operator can correct the position of the piston before introduction.

» Transmission system regulated with brushless motor.

» Entry force adjusted electronically.

» Locking of the rod, by manual pneumatic blockages system.

» Designed to lock cylinders with large or wide diameters, important weights and short strokes in this position, leaning on floor.

» Safety chain that is tensioned by a hydraulic service cylinder, to keep your cylinder in position.

» Application of a hydraulic cylinder which, when mechanically connected to the cylinder under test, generates a force of up to 5500 kg.

» Processing results on the Test Report.

» To be combined with hydraulic safety blocks.

DON’T WORRY!

WE GRANT ASSISTANCE

ASSISTANCE AND SUPPORT AT EACH STEP.

The value, efficiency and the precision of your machines are to be protected over time, through scheduled maintenance interventions. An optimal planning of the maintenance of assembly and test benches is just as important as the production planning within your company. You can imagine that a sudden “machine stop”, a failure, or even minor problems, are events to be prevented. Your production system should not be at risk. We therefore, propose periodic maintenance that can be planned: annually or every two years... Your production strategy is at stake: plan wisely to have the optimal functionality of your machine, and its highest performance as to ensure quality of your hydraulic cylinders.

ASSISTANCE

TICKET INVESTMENT

PROTECT YOUR

THE ASSISTANCE TICKET CONSISTS OF REMOTE ASSISTANCE GRANTED FOR AT LEAST 10 HOURS, FOR ANY NEED OF FURTHER TRAINING OR SUPPORT.

TRAINING PACKAGE

THE TRAINING SERVES TO LEARN THE USE OF THE MACHINE AND ITS SOFTWARE.

A STRATEGIC PRODUCTION CHOICE

Would you ever avoid the periodic inspection of your car?

For the same reasons, it is always reasonable and necessary to rely on regular, periodic and qualified assistance and maintenance in order to assure excellent performance of your test-assembly bench.

Our assistance packages guarantee a service of maximum reliability and support: in every situation or in every occasion of unexpected event; by assuring remote assistance, training in the workshop, the coverage of unexpected costs for failure of components.

ORDINARY MAINTENANCE

THE ORDINARY MAINTENANCE CONSISTS OF: PERIODICAL REPLACEMENT OF FILTERS, CHECK-UP ON THE MACHINE AND SOFTWARE STATUS.

CAREFREE MAINTENANCE

THE CAREFREE MAINTENANCE INCLUDES EXTENDED GUARANTEE ON MACHINE E X T R A - O R D I N A R Y INTERVENTIONS MAIN OR STRATEGICAL COMPONENTS OF MACHINE READY TO STOCK OR RESERVED

not only in the business of cylinders

OTHERPROJECTS

A.F.Automazione off ers a wide variety of products and project services.

Working in close collaboration with our customers, we always strive for understanding their needs, their goals and their processes in order to develop the best possible solution .

It is essential to provide reliable, eff ic ient and ful ly integrated solutions to help companies increase productivity, effi ciency and safety.

Glue dosing bench with UV lamps.

This project was developed to obtain a meticulous and precise dispensing of glue (adapted for the Diaphragm Kit) and the sub-sequent drying of the adhesive on the product, using UV lamps.

Precise dosing of the adhesive without waste.

Ergonomic workstation in favor of the operator.

Reduction of working times and better working environment.

Metal band punching machine.

Created as customized special meachine, it performs operations on metal band as to eliminate the component deformations, and to do bending and drilling.

The level of precision on this machine is very high.

The work is carried out perfectly and with no mistakes.

Automatic Warehouses.

Automatic warehouses make the management of goods in nowdays companies effi cient and immediate and smooth productive procedure

Maximum exploitation from the available space.

Reduction of archiving/searching/retrieval times..

Damage reduction and reduction of loss of assets.

© A.F. Automazione - Industrial Automation Systemdi Alberto FrittoliVAT N. IT00455590190 - C.F. FRTLRT63B14D150PVia Dosolo 13-15, 26030 Malagnino (Cremona) - ITALYTel. +39 0372 21098 - [email protected], www.afautomazione.it

industry 4.0

THE FOURTH INDUSTRIAL REVOLUTION

The imperative for companies is to digitize business, to optimize productivity, improve product quality, be fl exible and fast decision-making. The potential of new information technologies is destined to change current business models and the way of doing busines

• Data collection as a tool to create value;

• Data analysis to monitor and optimize production, guiding business decisions;

• The internal communication fl ow will be continuous and in real time between workstations, integrating production and warehouse;

• The ability to communicate will bring the self-diagnostic capability to the line and will allow remote control of production, while the fl exibility of the systems will allow the products to be customized according to demand;

• Evolution of human-machine interaction. Intelligent machines collaborate with the operator carrying out repetitive activities while people dedicate themselves to the function of greater added value;

• The essential task of controlling and correcting the production parameters, as well as the creative contribution, will remain a human privilege.

•EN ISO 14119:2013•BS EN 61310-3:2008•EN 60204-1:2006•CEI 44-5 Safety of machinery. Electrical equipment of machines.•The EMC Directive 2004/108CE

REFERENCE STANDARDS •D.Lgs. 9 Aprile 2008 n81 e s.m.i. (ITA)•Italian Standard CEI•2006/42 EC Machinery Directive.•2006 95 EC Low Voltage Directive

“Evolution of human-machine interaction. C o n t r o l l i n g a n d co r r e c t i n g , w i l l remain a human privilege”.

IT

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LOGY

www.afautomazione.it

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