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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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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Barrel agitator stations, used to process and stir casting resins, have to carry out a number of complex functions on resin barrels as large as 200 liters. For a long time, however, companies were using only modified machines from the painting industry, which lacked a number of safety features.

That’s why Bavarian-based company Scheugenpflug AG designed a new barrel agitator station using ACE industrial gas springs. These springs prevent damage to the machine in the event of sudden pneumatic failure.

Existing Challenges. Barrel agitator stations are responsible for the processing, stirring and controlled heating of flowing media. Used in applications with a high material consumption rate, they ensure a homogeneous potting material at certain temperatures. Until recently, however, only modified barrel agitator stations from the enameling and painting sectors were used to stir and process casting resins in large 200-liter barrels.

Not only that, but these machines failed to meet the specific demands of different casting resins.

To overcome these challenges, Scheugenpflug designed a new barrel agitator station with a special bell, which operators lower over the barrel to carry out a number of functions. The team, however, needed to integrate safety measures in the event of a sudden pressure drop, which would cause the lifting unit to fail and the bell to drop down towards the barrel. This scenario risks damage to the machine, as well as to the barrel itself.

Scheugenpflug contacted ACE to help design a solution.

ACE Industrial Gas Springs Improve Safety. ACE engineers selected industrial gas springs (type GS-40-1000), which would control the lowering of the bell in the event of pneumatic failure. These maintenance-free, adjustable components can handle forces from 2 to 2,923 pounds, provide up to a 39.37-inch stroke and operate via pressurized nitrogen gas. In this case, ACE engineers worked with Scheugenpflug onsite, carrying out a series of tests to determine how much gas needed to be loaded into the springs. Testing was a success, and Scheugenpflug engineers integrated the springs into their new machine.

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For more than 25 years, Blow Up Video Production has provided broadcast engineering services and equipment for a range of video and television projects around the world. With the help of profile dampers from ACE Controls, the company developed unique shipping cases, ensuring its cameras and other high-quality equipment could be transported to their various locations undamaged.

Avoiding Travel Accidents. The company saw many accidents in the past. Shipping cases were known to have been pierced by forklifts or dropped from damaging heights. “Air travel is another big source of potential trauma,” Martin Schiemann, who heads Blow Up, said. After several accidents resulting in equipment damage, Schiemann and his team decided to revamp the shipping cases with the help of ACE Controls.

ACE TUBUS Profile Dampers. ACE engineers recommended TUBUS TR67-40 profile dampers, which enable very long, yet soft deceleration with a gradual reduction of energy at the end of each stroke. Designed for radial damping, these dampers have an energy capacity of up to 204 in-lbs/cycle and a dynamic force range of 49 to 1,686 pounds.

Within each shipping case, equipment is placed on 19-inch stackable racks, each of which is supported by four TUBUS dampers. Engineers can also easily adapt the damping effect, depending on the weight of the equipment. “Thanks to the TUBUS dampers, we can guarantee that our equipment will arrive safely at any location in the world,” Schiemann said.

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When it comes to the cutting operations to make power cables, safety is key. That’s why Rittmeyer, a German-based precision engineering company, utilizes a high-tech, coax shielding cutting device called the BERI.CO.CUT. To make operation of this electro-pneumatic machine safer, Rittmeyer integrated ACE shock absorbers and clamping elements into its design.

End Position Protection. The BERI.CO.CUT precision-cuts the shielding and braids cables used in electric and hybrid vehicles. As the cables are being worked on, the head of the machine moves. To protect operating personnel and the machine itself, Rittmeyer, along with ACE specialists, selected miniature format MC75EUM-3 shock absorbers.

These maintenance-free, hydraulic elements ensure gentle impact of the head against the rear pane, preventing costly damage to both the head and overall structure. And with a net weight of only 30 grams, a length of 70 mm and a reset time of 0.3 seconds, ACE shock absorbers far exceeded the cable cutting machine’s compact requirements.

Pneumatic Rod Clamping. In addition to the shock absorbers, Rittmeyer selected ACE LOCKED PN clamping elements to use in its cable cutting machine. These components are designed to immediately clamp in the event the machine loses pressure as it moves concentrically along two guide shafts, protecting both the operators and the machine itself. They also prevent movement during the cutting process—a critical function, as even the slightest cutting inaccuracy can have serious repercussions in automotive or aerospace applications.

Suitable for rods with diameters of 20 to 40 mm, LOCKED PN clamping elements absorb forces axially and rotationally. With a holding force of up to 36,000 N, they also reach or exceed the levels of hydraulic clamps without the high cost.

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Dampening Free Fall
For their project, THM’s graduate engineering students were tasked with designing the control parameters that allow a quadrocopter to maintain a stable position during flight. Because quadrocopters can fly in loops or along tight curves, they also had to account for how the aircraft might fall, potentially making impact with the ground on more than one side. They therefore outfitted their quadrocopters with three shock absorbers from ACE, placing them on the top and bottom of the aircraft.

ACE Technical Features
The students chose ACE miniature shock absorbers (type SC650EUM-0), which are ideal for soft damping thanks to their long, 25.4 mm strokes that produce smooth deceleration and low reaction forces. These maintenance-free, ready-to-install hydraulic machine elements boast several design features and options that appealed to the THM students, including:

• An option to include a linear or progressive braking curve
• Integrated positive stop for use in automation applications
• 73 Nm/stroke energy capacity
• Operating temperature range of 0 to 66°C
• Load range of 1 to 2,000 kg

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