Christmas is around the corner. Due to the popularity of online shopping, the volume of packages is increasing. Sorting plants have to cope with these rising quantities—especially at peak times of the year. This demand places more pressure on sorting machines, which must be able to move at high speeds without losing packages.

Let’s explore how a new, high-end sorting system was experiencing vibration, which increased the risk that packages would fall off the conveyor. ACE miniature shock absorbers put a stop to this problem—ensuring fast, accurate deliveries.

A Leader in Sorting Machines
Equinox MHE provides turnkey logistic automation systems, including manual sorting, picking and warehouse management systems. Its sorting machines, in particular, integrate trays to transport products. When a product enters the machine, the system identifies it by scanning the barcode. A tray then transports the product to another station, where it is sorted, packed and shipped.

Troublesome Vibration Due to Tight Curves
Equinox MHE manufactures many kinds of sorting machines, including split tray sorters, which have a characteristic oval-shaped conveyor on which the trays circulate. To save on space, company engineers had designed a split tray sorter with a smaller curve radius. As a result of this design, the transported containers moved close together along the curves—causing vibration. In a worst-case scenario, this vibration could cause valuable cargo to fall off the conveyor.

To avoid this outcome, Equinox MHE contacted ACE.

ACE Mini Shock Absorbers Stop Centrifugal Forces
To meet this application’s requirements, ACE engineers installed MC150EUM miniature shock absorbers on the sorters. These maintenance-free devices feature a hermetically sealed rolling diaphragm, which completely separates the damping fluid from the surrounding air and also delivers low return forces. Despite their small size, they also have an energy capacity of 20 Nm per cycle—or 34,000 Nm per hour with a stroke of just 150 mm.

When installed in the split tray sorter, the shock absorbers instantly smoothed out the movements of the trays traveling along the curves—successfully reducing the troublesome vibration and eliminating the risk that packages would topple out.

In addition to packaging equipment, they’re suitable for a variety of automated applications, including material handling equipment, robotics, machine tools—and more.

Download the full case study to learn more.

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When a homeowner wanted to install a sushi freezer within a confined space without obstructing other nearby appliances, an ACE Controls gas spring played a vital role in economizing that space. Sean Moloney, the contractor working on the project, had to install the approximately $3,000 sushi freezer – which stores contents at temperatures down to -60ºF – along with a beverage refrigerator and countertops. In addition, he had to work with the following constraints:

• The sushi freezer was to be installed beneath a staircase, to the right of a beverage refrigerator (housed in a triangular cabinet) with a front-facing door.
• A 49-pound white oak countertop lid with a piano-type hinge had to open first, providing access to the freezer within the enclosure, which also opened from the top.
• Because a user can’t hold the heavy, wooden lid for long, it had to stay in place when opened.

Sean needed a gas spring that could support the heavy load and whose range of motion would provide maximum access when open, but without it hitting and damaging the angular stairway above the appliances. Understanding the investment the owner was laying out for the freezer, refrigerator and oak countertops, Sean knew that an inexpensive piston would not be sufficient for the job. He searched online for a gas spring with the quality that the project demanded and found acecontrols.com. He chose to install two GS-19-200-AA Push-type industrial gas springs to support the countertop lid. The heavy-duty gas springs offered the following features and characteristics:

• Able to handle forces from 2 to 2,923 pounds (10 to 13,000N).
• Extension force of 157 pounds.
• 7.87 inches of stroke.
• Body diameter of 0.31 to 2.76 inches (8 to 70 mm).
• Ready to install and requires zero maintenance.

Although Sean began the project with his own calculations, an ACE Controls engineer worked with him to revise his opening angle and range of motion. He also recalculated the mounting positions on the lid and cabinet. Taken together, these calculations provided an optimal fit.

You Can’t Put a Price On Safety
The homeowner’s main concern going into the project was user safety. Should the 49-pound lid fall on a user’s hands or hit the user on the head, it would likely cause serious injury. That’s why Sean opted for the premium quality of the ACE Controls GS-19-200-AA gas spring. He reports the industrial gas spring is supporting the weight of the countertop just fine, and the homeowner is really happy with it. Says Moloney, “it gives an assurance to the owner that it is a professionally engineered product.”

For more information about ACE Controls’ GS-19-200-AA Industrial Gas Spring, visit www.acecontrols.com.

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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.

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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.

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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.

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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.

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Sometimes even the simplest thing, like attaching wheels to a heavy object, can create engineering challenges—something Jorkisch recently overcame with the help of industrial gas springs from ACE Controls. Sometimes even the simplest thing, like attaching wheels to a heavy object, can create engineering challenges—something Jorkisch recently overcame with the help of industrial gas springs from ACE Controls.

The problem. In general, when wheels are mounted under uncontrolled weight, overcoming unevenness in the ground is difficult. Like a car driving over a bumpy road, the wheels, which must support the weight of the car, have the tendency to jerk left or right—causing potential damage to the wheels. To avoid this phenomenon, mounted wheels should be able to move freely without having to support the load.

The solution. To support the weight of the door, Jorkisch technicians integrated ACE industrial gas springs into the wheels’ metal supports. Depending on the size, these maintenance-free, adjustable components can handle forces up to 13,000 N, provide up to a 1,000-mm stroke and operate via pressurized nitrogen gas. ACE engineers fill the springs with the gas according to an application’s individual pressure requirements. In this case, technicians selected a 40-mm model (type GS-40-200), which can deliver forces up to 5,000 N.

The results. Thanks to the springs, camp personnel have been able to roll the wooden gate with ease despite the uneven ground—and the customer is confident the components will stand the test of time.

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To overcome this challenge, the university team added low-frequency pneumatic leveling mounts (PLMs) from ACE Controls to the bench. Here’s how these components successfully prevented unwanted vibration:

Vibrating Test Bench Threatened Equipment
According to the research team, the key to making drives more efficient lies in the engine’s oil pump—by reducing flow rate, then it is also possible to reduce power consumption. The students analyzed the hydraulic, volumetric and mechanical characteristics of various oil pumps to see how they could improve flow behavior—particularly, how to avoid leakage and reduce friction. As part of the test setup, they constructed a large 1,500-kg test bench and placed various equipment on top of it, including oil pumps and an electric motor that drove the pumps at a speed of 300 to 7,000 revolutions per minute.

These speeds, however, caused the bench to vibrate. Not only did the vibration cause the bench to shake, threatening the equipment on top of it, but the vibrations were strong enough to affect other test benches in the room.

ACE Leveling Mounts Reduce Vibration
The university team turned to ACE Controls. For the test bench, ACE engineers opted for six low-frequency pneumatic leveling mounts (PLMs), which isolate machines from undesirable vibrations and impact forces while maintaining perfect leveling. These components are suitable for low-frequency applications between 3 and 10 Hz, including high-speed presses, measuring tables, fans and air compressors.

Since integrating the ACE mounts, the test bench no longer shakes. The students can carry out their research without fear the vibration will affect their equipment and have been able to take important steps towards achieving more energy-efficient drive systems.

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Here’s how hydraulic dampers from ACE Controls overcame that challenge—while helping both farmers and the environment in the process.

Reducing Agricultural Drift
Drift creates a number of problems. For one, farmers require more costly chemicals. Because the amount that reaches the crops isn’t guaranteed, plants also tend to receive too much or too little—resulting in smaller yields. And finally, the excessive, wasteful spraying is harmful to the environment.

The Wingssprayer solves these problems. The concept is simple: the Wingssprayer integrates wings—much like the ones on an airplane— that push the plants down during spraying, creating downward streams of air that steer the chemical droplets into the deepest parts of the plants. In addition, these aerodynamic airstreams form a blanket of air over the crops behind the machine, preventing the drops from escaping. And finally, it sprays small droplets which, as opposed to the traditionally sprayed large drops, completely cover the crop with a fine mist.

ACE Hydraulic Dampers To The Rescue
But the Wingssprayer doesn’t just rely on wings. To operate safely, it utilizes hydraulic dampers (type HB-15-25) from ACE Controls. Otherwise, the sheer size of the Wingssprayer would cause it to shake during operation—to the point where the machine could damage itself.

The dampers, which resemble industrial gas springs, are adjustable—enabling engineers to stabilize movement in both the push and pull directions. ACE delivered a double-acting variant capable of a maximum compression force of 179.85 pounds, stabilizing the machine even on very windy days. Since integrating these components, the machine has operated safely and efficiently—and to this day, continues to have a positive impact on the environment.

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Elevators are usually in service for several decades, so it’s no wonder they have to be upgraded from time to time. When modernizing elevators, several factors have to be considered—like passenger comfort, handicap accessibility and motor noise.

In a recent application, a building elevator outfitted with a newer, larger motor was generating troublesome noise for nearby residents. Here’s how Cup Mounts from ACE Controls came to the rescue.

The Challenges Of An Upgraded Elevator
A+G pro GmbH specializes in elevators and building technology. In addition to installing new elevators, the company provides ongoing maintenance of existing ones to ensure current safety standards are being met. As can be expected, many older elevators need to be modernized.

The company recently upgraded the elevator in one apartment building to be more wheelchair-accessible. To do so, they removed the counterweight to enlarge the cabin. While the solution worked, it created a new set of challenges: because the balance in the elevator was no longer being compensated by the counterweight, the company had to install a larger motor.

This new motor generated a lot of noise, which nearby residents could hear from their bedrooms.

ACE Cup Mounts Reduce Motor Noise
A+G pro needed an easy, effective and inexpensive solution to this noise problem. That’s where ACE came in. For this application, ACE engineers selected their Cup Mount (CM) product family of rubber-metal isolators, which work by isolating the vibrations and impacts generated by machines and motors.

These components are characterized by their robustness, compact size and customizable installation length. They can be tilted in the x, y and z axes and can be used for all loads, including shear, compression and tension, up to 750 kg.

Once engineers installed the Cup Mounts in the elevator, all motor noise subsided. Not only did the elevator meet industry standards, but the nearby building residents could sleep soundly once again.

To learn more, download our latest case study.

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