While the machine was able to perform a variety of machining tasks, it was hindered by a recurring problem: Whenever an operator closed the access door, the door often bounced back in the opposite direction, creating additional, unwanted impacts and safety issues.

To ensure a controlled stop whenever an operator closes the door, the machine tool manufacturer implemented our MA225M miniature shock absorber. This maintenance-free, ready-to-install unit offers an energy capacity of 300 inch-pounds per cycle and 400,000 inch-pounds per hour. Available in a weight of 5 to 500 pounds, the shock absorber has a very short length of 4.67 inches and has a 0.75-inch stroke length. The MA225M provides soft damping with a return force range of 1.05 to 2.15 pounds, and it includes an integrated positive stop.

Thanks to the MA225M, the machine tool manufacturer was able to:

• Increase the door closure velocity, which in turn has increased production.
• Reduce the machine load.
• Ensure smooth damping whenever the door closes.
• Eliminate the possibility of operator injury.

Smooth, Controlled Closure Without Bounces
Access doors to powerful machines such as this turning-milling center are critical to keeping operators safe and nearby components undamaged. That means the damping devices that bear the doors’ frequent closures, as well as the machine’s constant operation, must be strong and reliable. A door that frequently bounces back is unacceptable.

Our miniature shock absorbers are designed to support up to 900 inch-pounds per cycle depending on the model, and they have a long operating lifetime that makes them well-suited for continuously operating equipment. When it comes to heavy-duty machinery, ACE Controls miniature shock absorbers can keep your access doors trouble-free.

For more information about our MA225M miniature shock absorbers, visit our product page.

The post Miniature Shock Absorbers Keep Turning-Milling Center Access Doors in Place appeared first on ACE Controls Inc..

Bottling companies are defined by their ability to turn out large quantities of product, and they typically ask a lot from their machines. A single machine can produce millions of units, and some are designed for versatility in order to accommodate production variables such as different types of bottle caps. In a high-volume industry like bottling, machine parts have to be reliable and offer long lifetimes. And when it’s time to replace a part, it must be easy to install.

One ACE customer, for example, built a “universal” capping machine capable of capping 1.4 million bottles each year with various types of tops: screw caps, pump dispensers and push-pull stoppers. It relies on ACE shock absorbers because they can always be easily integrated into existing constructions, and dampers subjected to constant loads can be quickly replaced at the end of their lifespan. This capping machine incorporates ACE MC150MH miniature shock absorbers in multiple locations.

Designed to offer high endurance and a very low resetting force, the self-compensating and ready-to-install MC150MH shock absorber features a high lifetime of up to 25 million cycles and trolling diaphragm technology that ensures the damping fluid is completely separated from the surrounding air. This technology allows for direct installation in a pressure chamber to provide end stop damping in pneumatic cylinders up to approximately 100 psi (7 bar). The shock absorber provides progressive energy capacity up to 175 inch-pounds per cycle and a 0.5-inch stroke. Additional features and specs of the MC150MH include:

• Integrated positive stop.
• A side load adapter to allow impact angles of up to 25 degrees.
• Stainless steel options.
• Universal mounting.

The MC150MH is also appropriate for a wide variety of applications such as material handling equipment, packaging equipment, medium robotics and machine tools. Customers can ensure the right fit using ACE Controls’ online sizing tool.

Reliability and Long Lifetime Maximize Machine Availability

When you need to protect high-volume manufacturing equipment, your shock absorber’s reliability and lifetime can make a difference in machine availability. ACE Controls’ MC150MH boasts a long cycle life plus easy installation so your machine will require less downtime for repair or replacement and deliver greater productivity.

For more information about ACE Controls’ MC150MH miniature shock absorber, visit our product page.

The post Miniature Shock Absorbers Improve Capping Machine Reliability appeared first on ACE Controls Inc..

When it comes to thermoforming machinery, ensuring the safety of nearby workers is a critical aspect of their design. Not only do these machines weigh several tons, they have many moving parts, built-in heating ovens and presses that require a barrier to separate workers from dangerous functions. In general, once the machine is up and running in automatic mode, there should be little employee involvement with the machine — unless or until something goes wrong with the equipment or when maintenance is needed.

To provide access, thermoforming machines have heavy doors or hoods that must stay open long enough for the worker to complete their task. One ACE customer built a thermoforming machine to include a clear glass access hood that weighs more than 110 pounds. They needed to add a support mechanism to hold the heavy door in the open position.

They chose an ACE Controls GS-22-300-CC-VA gas spring. This push-type gas spring with 11.81-inch stroke has a maximum extension force of 247 pounds — an ideal amount of muscle to support heavy loads, and a lifetime of approximately 250,000 cycles, making it well-suited for heavy-duty applications like thermoforming machines. The GS-22-300-VA Series is part of ACE’s industrial family of gas springs with extension force capabilities ranging from 2 to 2,923 pounds (10 to 13,000N) and body diameters from 0.31 to 2.76 inches (8 to 70 millimeters). Additional features and specifications include:

• Stainless steel construction and a wear-resistant steel piston rod.
• An end position damping length of approximately 0.79 to 2.76 inches (depending on the stroke).
• A design that allows for mounting in any position, although mounting with the piston rod downwards is most effective.

To get the proper size and fit for, customers can access ACE Controls’ online sizing and configuration tool and enter details about the intended installation. The tool will generate interactive 2D and 3D simulations that the user can rotate, tilt and zoom.

Thanks to an ACE Controls industrial gas spring, the thermoforming machine builder is able to keep the heavy glass hood open for as long as needed without worrying about the hood injuring operators or maintenance personnel.

Reliable Gas Springs Ensure Worker Safety

Because hoods on thermoforming machines are critical to keeping nearby people safe, the devices that bear their heavy weight and ensure their functionality must be strong and reliable. A hood that closes prematurely is unacceptable. ACE Controls push-type industrial gas springs are designed to support loads as high as nearly 3,000 pounds, depending on the model, and have a long operating lifetime. For your heavy-duty machinery like thermoforming equipment, it pays to have industrial gas springs under the hood.

For more information about the ACE Controls GS-22-300-VA industrial gas spring, visit our product page.

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The post Gas Springs Keep Thermoforming Machine Hoods in Position appeared first on ACE Controls Inc..

Averna is a test and quality engineering systems integrator, that serves thousands of clients worldwide. One of their clients is a major player in the medical device industry segment. This client approached Averna with a partnership to develop a new test method for medical pump evaluation. The client chose to work with Averna because of their excellent reputation and vast medical device testing experience.

There were many challenges to overcome while creating this test system. Averna needed to create an automated control system with specific and precise properties to speed up medical pump testing. The testing unit also needed:

• Functionality that would allow it to be elevated for sterilization and cleaning beneath the unit
• Motion control while lifting and lowering to prevent damage
• A feature that would increase ease of use and safety for the operator

For this requirement, Averna reached out to ACE.

Averna started their search online and came across the ACE gas spring sizing tool. Alexander Sutton of Averna said, “the gas spring calculator for selection was a huge time saver.” The ideal gas spring for this application was a stainless-steel pull type. Many varieties of ACE gas springs are offered in stainless steel, which is commonly used in medical and food industries. Stainless steel is used because it will not rust. A pull type gas spring is needed when there are space restrictions for mounting, which was the case here.

The new system developed through this partnership was much more accurate than the previous system and reduced testing time by over 80%. This single system was able to replace multiple testers to accomplish the same throughput with much higher accuracy.

Why choose ACE? Averna stated they benefitted from the simplicity of use of the gas springs, also the ease of getting support through the website. Alexander Sutton of Averna said, “the support staff was very helpful and available for questions throughout the duration of the project.”

Take advantage of ACE on your next project! Online resources are available quickly and easily. Size, configure, and buy shock absorbers or gas springs directly from the website. In stock items in the ACE web shop will ship within 3 business days. As always ACE is available for any support you need – give us a call or email shocks@acecontrols.com.

Contact Us

The post Testing Solution Innovator, Averna, Uses ACE Gas Springs appeared first on ACE Controls Inc..

However, industrial gas springs like the GS Series are appropriate for more than lifting and closing flaps. In fact, industrial gas springs can be used in winding-type applications. Recently KOHLS Maschinenbau GmbH incorporated ACE industrial gas springs into vertical taping machines used to wind coils around a large transformer.

Winding a large transformer core with resin tape comes with a challenge: The transformer’s oval legs’ right angled cross-sections can cause a drop in belt tension. The interruption undermines a flat, uniform winding where a variation by even one millimeter is unacceptable. The company needed to add an industrial gas spring to the taping machine’s brake system. By using the gas spring’s stroke path as a backup during interruptions, proper belt tension can be maintained. KOHLS chose an ACE Controls GS19-150-EE user-adjustable push-type gas spring with a stroke length range of 50 to 300 millimeters.

Based on the application requirements, ACE filled the GS19 with the right amount of pressurized nitrogen to get the desired pressure force. If the gas spring required further adjustment, the GS19 — like ACE Controls’ other industrial gas springs — comes with a built-in relief valve. KOHLS’ GS19-150-EE engineered solution now provides an extension force of 550 Newtons, and its 152-millimeter reserve travel distance maintains a constant tape tension that withstands interruptions. The result: uniform and even windings around the multi-ton transformer core, and KOHLS has optimized its transformer coil-winding process.

The successful transformer coil-winding application is a good example of how ACE Controls’ industrial gas springs combine strength, durability, sizing options and adjustability to give you an engineered solution to match your lifting, lowering or load-handling requirements.

For more information about ACE Controls’ industrial gas springs, visit www.acecontrols.com.

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The post Large Transformer Core Windings: A Gas Spring Application With A Twist appeared first on ACE Controls Inc..

Challenge #1: Moving Masses
It’s not always possible to mount your shock absorber in the center of a moving mass—which is often the case in Cartesian robot systems. For one, moving masses have a wide impact surface, which can make it difficult to place your shock absorber exactly in the middle.

ACE tip. To avoid torsion in these types of applications, simply mount two shock absorbers on the left and right of the outer impact area of the mass. Make sure that you mount both dampers at the same height, however, otherwise they won’t be parallel.

Challenge #2: Limited Mounting Space
Sometimes your application might not have enough space to mount a large damper. Again, the solution is to mount several smaller dampers in parallel. This kind of mounting will effectively decelerate your moving mass despite the limited space.

ACE tip. Use self-compensating dampers, which you can size according to the exact stiffness requirements of your application. This ensures every damper of the same model and weight will have the same stiffness and damping characteristics. Adjustable dampers, on the other hand, are too difficult to adjust equally—creating differences in stiffness that can cause the moving mass to impact each damper differently.

Size Your Damper In Minutes
Using our free calculation program and online sizing tool, you can size shock absorbers and gas springs for nearly any load and direction within minutes. For particularly difficult or complex applications, our application engineers are ready to help.

To get started, visit www.acecontrols.com/us/calculations.html.

Use Our Free Calculator  

The post ACE Tips: How to Mount Two Shock Absorbers in Parallel appeared first on ACE Controls Inc..

Here’s a look at how the oversized safety shock absorbers—capable of stopping 4,000-ton cargo ships—are key to protecting the lock gate and ensuring the safety of the ships passing through.

Like Navigating A Tight Parking Spot
During the design phase of the ship lock system, Dutch construction and steel company Mourik Lumburg had to take into account the fact that ships may touch the safety beam while navigating into the lock. The action resembles the way a car, as its driver navigates a tight parking spot, might tap the car next to it. But with loaded vessels weighing up to 4 million kg and traveling at 0.5-m/s speeds, the gate would need to withstand a considerable amount of force.

Mourik technical experts needed large, heavy-duty shock absorbers that could protect the gate. They approached ACE Controls for a solution.

An Extra-Large Solution
ACE technical experts calculated that the shock absorbers would need to withstand 500,000 Nm of energy—requiring a customized design. Weighing in at 320 kg, these special oversized shock absorbers feature a length of 2,649 mm, outer diameter of 200 mm and stroke of 800 mm.

After the collision in the Netherlands ship lock, engineers installed a new beam on the gate—a process that required temporary disassembly of the shock absorbers. During this process, ACE technical experts were on hand to provide the repair team with all the necessary support on how to remove and then reinstall the dampers.

Thanks to these extra-large components, the ACE and Mourik teams are confident the ship lock will continue to operate safely for many more years.

To learn more, download our latest case study.

Download The Case Study  

The post Extra-Large Shock Absorbers Keep Ship Lock Intact Despite Collision appeared first on ACE Controls Inc..

For motion systems, crashes can be catastrophic—causing anything from inconvenient repairs to costly system downtime. One company, however, has successfully found a way to minimize the dangers of crashes on its linear axes using profile dampers from ACE Controls. You can easily install these small, yet durable components on rails as end-position dampers, protecting both the components and larger system in the event of a crash.

Let’s take a look at how ACE profile dampers did the trick:

Controlling Impact In The End Position

LISCO specializes in designing and manufacturing various motion control products, from individual axes to entire linear axis systems. Recently, the company sought to improve the safety of its linear axes, which are used in many demanding applications, including material handling and delivery systems. Specifically, LISCO needed a way to control the impact in the end position should a software error or power failure occur. The resulting damage could lead to very costly repairs or even downtime for the entire system.

ACE Profile Dampers Fit The Bill

Since LISCO’s linear axes include profile rails and guides, it made sense to find a compact, easy-to-install solution that engineers could simply attach to the left and right of each rail. TUBUS profile dampers (type TA17-7) from ACE Controls fulfilled these requirements.

TUBUS profile dampers feature a copolyester elastomer—a material that only heats up slightly and ensures consistent damping during operation. These components are also a cost-effective alternative to hydraulic dampers, saving money on the overall construction of the linear system without compromising safety. Additionally, they feature a space-saving size of 12 to 116 mm and can be installed quickly and easily using a special screw.

After integrating the dampers on its equipment, LISCO couldn’t be happier with the results. The company is now confident its linear axes will remain protected from crashes—should failure ever occur.

To learn more, download our latest case study.

Download The Case Study  

The post ACE Profile Dampers Protect Motion Systems From Dangerous Crashes appeared first on ACE Controls Inc..

Here’s how these components met the demands of the actuator—and improved the overall safety of the oil refinery:

Special Safety Valves Open 50 Times Faster. The oil refinery, located in Yanbu, condenses and liquefies natural gas for transport using explosion-proof compressors, which regulate the pressure in the pipes. If the pressure dips too low, the compressors switch on. If the pressure gets too high, they switch off. To ensure these compressors maintain the right working pressure while simultaneously avoiding overpressure, DGI developed special pneumatic actuators. Should overpressure occur, the system’s built-in pneumatic cylinder opens the large, 24-inch safety valve. Normally, throttle valves open at a speed of one second per inch—but DGI designed its valves to open 50 times faster.

At the same time, DGI needed a way to safely absorb the energy generated by the valves as they opened. The company teamed up with ACE Controls to incorporate hydraulic shock absorbers that could emergency-stop the piston rods on the cylinders.

MAGNUM Shock Absorbers: The Last Line Of Defense. Due to the small size of the actuators, ACE engineers selected their compact, yet powerful MAGNUM industrial shock absorbers (type MA3325). When the valves open, the rod makes contact with the shock absorbers, which engineers positioned in the front and rear of the cylinder. The dampers then fully stop and control the piston rod as it moves horizontally.

Without the absorbers in place as the system’s final safety measure, a number of devastating things could happen. The cylinder, actuator and compressor could experience irrevocable damage. Toxic gas could also leak out and potentially trigger an explosion—endangering personnel, the environment and other nearby facilities.

For these reasons, ACE shock absorbers are part of the Yanbu success story—and have improved the overall safety of the plant. To learn more about this application, download our latest case study.

Download The Case Study  

The post ACE Industrial Shock Absorbers Improve Oil Refinery Safety Valves appeared first on ACE Controls Inc..

E2M engineers needed a way to absorb these forces and avoid structural damage in the event of an emergency stop. Here’s how the company found a solution in profile dampers and safety bumpers from ACE Controls.

Dampers And Bumpers Provide Maximum Safety
Because E2M’s motion systems need to be able to support several tons, ACE engineers recommended a combination of two products-profile dampers and safety bumpers from the TUBUS TA and TC families, respectively.

TUBUS TA profile dampers provide high energy absorption up to 73% between 2 and 2,951 Nm. Made out of copolyester elastomer, these compact components provide consistent damping in a variety of applications.

TUBUS TC safety bumpers, also made of copolyester elastomer, were developed for crane systems and meet OSHA and CMAA international industry standards. As such, these rugged components provide high energy absorption up to 64% between 450 and 17,810 Nm-even in emergency stop situations.

Download The Case Study  

The post ACE Dampers And Safety Bumpers Absorb Forces In Motion Simulators appeared first on ACE Controls Inc..