ZURCON L-CUP
Introduction
The rod sealing system is the most critical part of a hydraulic cylinder. Therefore it is expected that a rod sealing system performs under leak-free conditions in the static and dynamic state. Moreover it has to fulfil the lifetime of several thousand hours.
To meet these requirements, Busak+Shamban has developed the ZurconR L-CupR*, a highly effective and innovative rod sealing component.
*Patent for: Europe No. EP 0724693
*Patent for: US No. 5,649,711
*Patent for: China No. ZL 94193869.7
Zurcon L-Cup is a trade name.
Description
Zurcon L-Cup is a single acting polyurethane rod seal with a unique design offering a hydrodynamic backpumping ability over the complete working pressure range. The pressure-independent, hydrodynamic sealing ability of this new sealing element requires no lubrication reservoir in the sealing area and ensures a constant and controlled pressure distribution over a wide pressure range. Additionally, the seal’s dynamic sealing edge has a highly effective friction-reducing microstructure**. This structure creates a constant lubrication film to prevent dry running, thus enabling an increased service life.
The advantages of the new Zurcon L-Cup design lead to the following improved properties:
Advantages
– Hydrodynamic back-pumping ability over the complete working pressure range
– Low friction and therefore a reduction of heat generated
– Low breakout force even after a long period of non-operation
– Very low stick-slip
– Low increase in friction at increasing pressure
– High extrusion resistance
– Optimum geometry of the static sealing lip for higher sealing ability
– No entrapped oil and grease between seal and groove (due to notches)
– No pressure build-up between seal and groove OD
– Long service life
The new Zurcon L-Cup was designed in accordance with customers’ demands.
– Groove dimensions according to ISO 5597 Part 2
– Interchangeable with existing U-Cup grooves
– Installation into closed grooves
– Wear and extrusion resistant high-performance polyurethane
** Patent No. DE4300889C1
Application Examples
Zurcon L-Cup can be used in all applications in which
previously a conventional U-Cup was applied, such as:
- Fork lifts
- Agricultural machines
- Light and medium mobile hydraulics
- Industrial hydraulics
- Machine tools
- Injection moulding machines
- hydraulic presses.
Another preferred solution for tandemrod sealing systems is the combination with the TurconR StepsealR K as primary seal and L-CupR as secondary seal, in conjunction with a double acting scraper.
Technical Data
Operating conditions
Pressure: Up to 40 MPa
Velocity: Up to 0.5 m/s
Temperature:-30_C to +80_C
Media: Hydraulic fluids based on mineral oil
Important Note:
The above data are maximum values and cannot be used at the same time. e.g. the maximum operating speed depends on material type, pressure, temperature and gap value.
Materials
Zurcon Z04
Special polyurethane Shore A 93
Colour: turquoise
Method of Operation
Busak+Shamban’s experience in the production of hydrodynamic back-pumping seals such as Turcon Stepseal K, and the use of Finite Element Analysis (FEA) and other laboratory tests have led to the development of Zurcon L-Cup. The main objective in the development of this seal was the ability to achieve an optimum pressure distribution over the complete pressure range.
The pressure distribution curve under the sealing lip needs to have a steep gradient on the high-pressure side and a shallow gradient on the rear of the seal.
operating principles and function of Zurcon L-Cup is similar to the well-known Turcon Stepseal K.
Friction
In Figure 34 the friction values of a conventional U-Cup and of Zurcon L-Cup are being compared. A high increase in friction of the U-Cup is clearly shown between approximately 5 and 15 MPa. This is due to the U-Cup being totally pressed on the rod surface at increased pressure, causing elimination of the oil reservoir and dry running of the U-Cup.
In comparison, the L-Cup shows only a low increase in friction which is due to the smaller contact area and better tribological behaviour. The result is a very low friction heat generation.
Surface microstructure reduces the effective contact area to the rod and therefore the breakout and dynamic friction are reduced compared to seals with smooth sealing surfaces. The hollow spaces between the peaks of the seal and the rod are filled with oil even during long periods without operation. When starting the movement after this period, a lubrication film is still present. This reduction of a large surface contact area into many small contact points also prevents excessive breakout friction and stick-slip.
During short stroke oscillation, oil is retained in the microstructures. This result would be unlikely with smooth sealing surfaces where full contact with the rod causes the oil to be pressed out.
Friction Heat
The effect described above can be made visible by simply measuring the temperature. Figure 36 shows the increase in temperature on the rod surface caused by friction, measured at a pressure of 40 MPa after 20 000 cycles. This explains the prolonged service life of L-Cup.
Test Conditions (Fig. 36)
Dimension: 50 x 60 x 11 mm
Pressure: 0/40 MPa
Velocity: 0.1 m/s
Temperature: ambient
Sealing Gap
The recommended gap dimensions described in Figure 37, depend on pressure and temperature.
Design Instructions
Lead-in chamfers
In order to avoid damage to the rod seal during installation, lead-in chamfers and rounded edgesmust be provided on the piston rods. If this is not possible for design reasons, a separate installation tool must be used.
The minimum length of the lead-in chamfer depends on the profile size of the seal and can be seen from the following tables.
Installation Recommendation
| Rod Dia. | Groove Dia. | Groove Width | Ra- dius | Ring Width | Order No. | |||||||||||||
| dN f8 |
D H10 |
L +0.25 |
r max. |
T | ||||||||||||||
| 6 | 10 | 4,5 | 0,2 | 3,6 | RLM000060-Z04 | |||||||||||||
| 8 | 12 | 3,6 | 0,2 | 3,2 | RLM000080-Z04 | |||||||||||||
| 8 | 16 | 5,0 | 0,3 | 4,2 | RLS400080-Z04 | |||||||||||||
| 8 | 16 | 6,3 | 0,3 | 5,7 | RLS100080-Z04 | |||||||||||||
| 10 | 18 | 6,3 | 0,3 | 5,7 | RLS100100-Z04 | |||||||||||||
| 12 | 16 | 3,6 | 0,2 | 3,2 | RLM100120-Z04 | |||||||||||||
| 12 | 17 | 4,0 | 0,3 | 3,6 | RLM000120-Z04 | |||||||||||||
| 12 | 20 | 6,3 | 0,3 | 5,7 | RLS100120-Z04 | |||||||||||||
| 12 | 22 | 8,0 | 0,3 | 7,2 | RLS500120-Z04 | |||||||||||||
| 14 | 22 | 6,3 | 0,3 | 5,7 | RLS100140-Z04 | |||||||||||||
| 15 | 21 | 5,0 | 0,3 | 4,5 | RLM000150-Z04 | |||||||||||||
| 15 | 23 | 5,0 | 0,3 | 4,2 | RLS400150-Z04 | |||||||||||||
| 16 | 22 | 6,0 | 0,3 | 5,4 | RL38N0160-Z04 | |||||||||||||
| 16 | 24 | 6,3 | 0,3 | 5,7 | RLS100160-Z04 | |||||||||||||
| 18 | 26 | 6,3 | 0,3 | 5,7 | RLS100180-Z04 | |||||||||||||
| 20 | 26 | 5,5 | 0,3 | 5,0 | RLM000200-Z04 | |||||||||||||
| 20 | 28 | 6,3 | 0,3 | 5,7 | RL08N0200-Z04 | |||||||||||||
| 22 | 28 | 5,0 | 0,3 | 4,5 | RLM100220-Z04 | |||||||||||||
| 22 | 29 | 5,6 | 0,5 | 5,0 | RLS000220-Z04 | |||||||||||||
| 22 | 30 | 6,3 | 0,3 | 5,7 | RL08N0220-Z04 | |||||||||||||
| 22 | 30 | 7,0 | 0,3 | 6,3 | RL09N0220-Z04 | |||||||||||||
| 25 | 33 | 6,3 | 0,3 | 5,7 | RLS100250-Z04 | |||||||||||||
| 25 | 35 | 8,0 | 0,3 | 7,2 | RLS500250-Z04 | |||||||||||||
| 26 | 36 | 11,0 | 0,3 | 9,9 | RL17N0260-Z04 | |||||||||||||
| Rod Dia. | Groove Dia. | Groove Width | Ra- dius | Ring Width | Order No. | |||||||||||||
| dN f8 |
D H10 |
L +0.25 |
r max. |
T | ||||||||||||||
| 28 | 36 | 6,3 | 0,5 | 5,7 | RLS100280-Z04 | |||||||||||||
| 28 | 38 | 8,0 | 0,3 | 7,2 | RL14N0280-Z04 | |||||||||||||
| 28 | 38 | 11,0 | 0,3 | 9,9 | RL17N0280-Z04 | |||||||||||||
| 28 | 40 | 9,5 | 0,3 | 8,1 | RLM000280-Z04 | |||||||||||||
| 30 | 38 | 6,3 | 0,3 | 5,7 | RLM000300-Z04 | |||||||||||||
| 30 | 38 | 8,0 | 0,3 | 7,2 | RL10N0300-Z04 | |||||||||||||
| 30 | 40 | 11,0 | 0,3 | 9,9 | RLM100300-Z04 | |||||||||||||
| 32 | 40 | 7,0 | 0,3 | 6,3 | RLM000320-Z04 | |||||||||||||
| 32 | 42 | 8,0 | 0,3 | 7,2 | RL14N0320-Z04 | |||||||||||||
| 32 | 42 | 11,0 | 0,3 | 9,9 | RLM100320-Z04 | |||||||||||||
| 32 | 47 | 11,0 | 0,3 | 9,9 | RL24N0320-Z04 | |||||||||||||
| 35 | 43 | 6,3 | 0,3 | 5,7 | RLM000350-Z04 | |||||||||||||
| 35 | 45 | 8,0 | 0,3 | 7,2 | RL14N0350-Z04 | |||||||||||||
| 35 | 45 | 11,0 | 0,3 | 9,9 | RL17N0350-Z04 | |||||||||||||
| 36 | 44 | 6,3 | 0,5 | 5,7 | RLS100360-Z04 | |||||||||||||
| 36 | 46 | 6,9 | 0,3 | 5,5 | RLM000360-Z04 | |||||||||||||
| 36 | 46 | 10,0 | 0,3 | 9,0 | RL16N0360-Z04 | |||||||||||||
| 36 | 46 | 8,0 | 0,3 | 7,2 | RLS500360-Z04 | |||||||||||||
| 37 | 47 | 11,0 | 0,3 | 9,9 | RL17N0370-Z04 | |||||||||||||
| 38 | 48 | 11,0 | 0,3 | 9,9 | RL17N0380-Z04 | |||||||||||||
| 38 | 45 | 7,0 | 0,3 | 6,3 | RLM000380-Z04 | |||||||||||||
| 38 | 55 | 10,7 | 0,3 | 9,2 | RL39N0380-Z04 | |||||||||||||
| 38,6 | 50 | 8,0 | 0,3 | 7,2 | RL37N0386-Z04 | |||||||||||||
| 40 | 48 |
|
0,3 | 5,7 | RLM400400-Z04 | |||||||||||||
| 40 | 48 | 7,0 | 0,3 | 6,3 | RL09N0400-Z04 | ||
| 40 | 48 | 9,0 | 0,3 | 8,1 | RL11N0400-Z04 | ||
| 40 | 50 | 7,0 | 0,3 | 6,3 | RL40N0400-Z04 | ||
| 40 | 50 | 8,0 | 0,3 | 7,2 | RLS500400-Z04 | ||
| 40 | 50 | 10,0 | 0,3 | 9,0 | RL16N0400-Z04 | ||
| 40 | 50 | 11,0 | 0,3 | 9,9 | RL17N0400-Z04 | ||
| 40 | 52 | 9,0 | 0,3 | 8,1 | RLM500400-Z04 | ||
| 40 | 55 | 9,4 | 0,4 | 8,1 | RLM000400-Z04 | ||
| 45 | 53 | 8,0 | 0,3 | 7,2 | RL10N0450-Z04 | ||
| 45 | 53 | 9,0 | 0,3 | 8,1 | RL11N0450-Z04 | ||
| 45 | 55 | 8,0 | 0,3 | 7,2 | RL14N0450-Z04 | ||
| 45 | 55 | 10,0 | 0,3 | 9,0 | RL16N0450-Z04 | ||
| 45 | 60 | 9,4 | 0,4 | 8,1 | RLM000450-Z04 | ||
| 46 | 56 | 11,0 | 0,3 | 9,9 | RL17N0460-Z04 | ||
| 48 | 60 | 11,0 | 0,3 | 9,9 | RL36N0480-Z04 | ||
| 50 | 58 | 8,0 | 0,3 | 7,2 | RL10N0500-Z04 | ||
| 50 | 58 | 9,0 | 0,3 | 8,1 | RL11N0500-Z04 | ||
| 50 | 60 | 8,0 | 0,3 | 7,2 | RLS500500-Z04 | ||
| 50 | 60 | 10,0 | 0,3 | 9,0 | RL16N0500-Z04 | ||
| 50 | 60 | 11,0 | 0,3 | 9,9 | RL17N0500-Z04 | ||
| 50 | 65 | 11,0 | 0,4 | 9,9 | RLM200500-Z04 | ||
| 50 | 65 | 12,5 | 0,4 | 11,3 | RL26N0500-Z04 | ||
| 52 | 62 | 11,0 | 0,3 | 9,9 | RL17N0520-Z04 | ||
| 55 | 63 | 9,0 | 0,3 | 8,1 | RL11N0550-Z04 | ||
| 55 | 65 | 8,0 | 0,3 | 7,2 | RL14N0550-Z04 | ||
| 55 | 65 | 10,0 | 0,3 | 9,0 | RL16N0550-Z04 | ||
| 55 | 65 | 11,0 | 0,3 | 9,9 | RL17N0550-Z04 | ||
| 55 | 70 | 11,0 | 0,4 | 9,9 | RLM400550-Z04 | ||
| 56 | 71 | 12,5 | 0,4 | 11,3 | RL26N0560-Z04 | ||
| 58 | 68 | 11,0 | 0,3 | 9,9 | RL17N0580-Z04 | ||
| 60 | 68 | 9,0 | 0,3 | 8,1 | RL11N0600-Z04 | ||
| 60 | 70 | 10,0 | 0,3 | 9,0 | RL16N0600-Z04 | ||
| 60 | 70 | 11,0 | 0,3 | 9,9 | RL17N0600-Z04 | ||
| 60 | 75 | 12,5 | 0,4 | 11,3 | RL26N0600-Z04 | ||
| 63 | 75 | 9,6 | 0,3 | 8,6 | RL20N0630-Z04 | ||
| 63 | 75 | 10,0 | 0,3 | 9,0 | RLM000630-Z04 | ||
| 63 | 78 | 12,5 | 0,4 | 11,3 | RL26N0630-Z04 | ||
| 65 | 73 | 7,0 | 0,3 | 6,3 | RL09N0650-Z04 | ||
| 65 | 75 | 10,0 | 0,3 | 9,0 | RL16N0650-Z04 | ||
| Rod Dia. | Groove Dia. | Groove Width | Ra- dius | Ring Width | Order No. | ||
| dN f8 |
D H10 |
L +0.25 |
r max. |
T | |||
| 65 | 75 | 11,0 | 0,3 | 9,9 | RL17N0650-Z04 | ||
| 68 | 78 | 11,0 | 0,3 | 9,9 | RL17N0680-Z04 | ||
| 70 | 80 | 8,0 | 0,3 | 7,2 | RL14N0700-Z04 | ||
| 70 | 80 | 10,0 | 0,3 | 9,0 | RL16N0700-Z04 | ||
| 70 | 85 | 12,5 | 0,4 | 11,3 | RL26N0700-Z04 | ||
| 75 | 85 | 10,0 | 0,3 | 9,0 | RL16N0750-Z04 | ||
| 75 | 85 | 11,0 | 0,3 | 9,9 | RL17N0750-Z04 | ||
| 75 | 90 | 12,5 | 0,3 | 11,3 | RL26N0750-Z04 | ||
| 80 | 92 | 9,6 | 0,3 | 8,6 | RLM000800-Z04 | ||
| 80 | 95 | 12,5 | 0,4 | 11,3 | RL26N0800-Z04 | ||
| 80 | 100 | 12,5 | 0,6 | 10,8 | RLM100800-Z04 | ||
| 80 | 100 | 16,0 | 0,6 | 14,4 | RL30N0800-Z04 | ||
| 85 | 100 | 13,1 | 0,4 | 11,8 | RL27N0850-Z04 | ||
| 90 | 105 | 13,1 | 0,4 | 11,8 | RL27N0900-Z04 | ||
| 90 | 105 | 12,5 | 0,4 | 11,3 | RL26N0900-Z04 | ||
| 90 | 110 | 12,5 | 0,6 | 10,8 | RLSA00900-Z04 | ||
| 95 | 110 | 13,1 | 0,4 | 11,8 | RL27N0950-Z04 | ||
| 100 | 120 | 12,5 | 0,6 | 10,8 | RLSA01000-Z04 | ||
| 100 | 120 | 16,0 | 0,6 | 14,4 | RL30N1000-Z04 | ||
| 101,6 | 114,3 | 10,6 | 0,6 | 9,5 | RLE304000-Z04 | ||
| 105 | 125 | 12,5 | 0,6 | 10,8 | RL29N1050-Z04 | ||
| 110 | 125 | 12,0 | 0,4 | 10,8 | RL25N1100-Z04 | ||
| 110 | 130 | 16,0 | 0,6 | 14,4 | RL30N1100-Z04 | ||
| 115 | 135 | 16,0 | 0,6 | 14,4 | RL30N1150-Z04 | ||
| 119 | 134 | 9,4 | 0,4 | 8,1 | RL22N1190-Z04 | ||
| 120 | 135 | 12,5 | 0,4 | 11,3 | RL26N1200-Z04 | ||
| 120 | 140 | 12,5 | 0,6 | 10,8 | RLSA01200-Z04 | ||
| 120 | 140 | 16,0 | 0,6 | 14,4 | RL30N1200-Z04 | ||
| 125 | 140 | 12,0 | 0,4 | 10,8 | RL25N1250-Z04 | ||
| 125 | 145 | 16,0 | 0,6 | 14,4 | RL30N1250-Z04 | ||
| 130 | 150 | 16,0 | 0,6 | 14,4 | RL30N1300-Z04 | ||
| 135 | 155 | 16,0 | 0,6 | 14,4 | RL30N1350-Z04 | ||
| 140 | 160 | 16,0 | 0,6 | 14,4 | RL30N1400-Z04 | ||
| 142 | 157 | 9,4 | 0,4 | 8,1 | RL22N1420-Z04 | ||
| 150 | 170 | 12,5 | 0,6 | 10,8 | RL29N1500-Z04 | ||
| 150 | 170 | 16,0 | 0,6 | 14,4 | RL30N1500-Z04 | ||
| 160 | 180 | 12,5 | 0,6 | 10,8 | RLSA01600-Z04 | ||
| 160 | 180 | 16,0 | 0,6 | 14,4 | RL30N1600-Z04 | ||
| 160 | 185 | 16,0 | 0,8 | 13,5 | RLSC01600-Z04 | ||
| 180 | 205 | 20,0 | 0,8 | 18,0 | RL32N1800-Z04 | ||
| 195 | 220 | 20,0 | 0,6 | 18,0 | RL32N1950-Z04 | ||
| 200 | 220 | 16,0 | 0,6 | 14,4 | RL30N2000-Z04 | ||
| 200 | 225 | 20,0 | 0,8 | 18,0 | RL32N2000-Z04 | ||
| 220 | 240 | 16,0 | 0,6 | 14,4 | RL30N2200-Z04 | ||
| 220 | 250 | 20,0 | 0,8 | 16,2 | RLSE02200-Z04 | ||
| 250 | 280 | 20,0 | 0,8 | 16,2 | RLSE02500-Z04 | ||
Beoordelingen
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