Correct hydraulic cylinder selection directly determines the performance, reliability, and lifespan of the system. Improper sizing can lead to numerous problems, from energy waste to premature failures. In this technical guide, we share the critical engineering parameters and calculation methods that should be potential candidates for cylinder selection.
Basic Formula
F = P × A | Force (kN) = Pressure (bar) × Area (cm²) × 0.1
1. Basic Selection Criteria
Five basic parameters are decisive in hydraulic cylinder selection: required force, stroke distance, operating pressure, movement speed, and operating environment. Correct determination of these parameters is a prerequisite for optimum cylinder selection.
1.1. Force Calculation
The first step is to determine the net force required by the application. Friction losses, load dynamics, and safety factors must be taken into account in calculations.
- Static Load: Nominal force is sufficient for static loads
- Dynamic Load: Acceleration force is added for moving loads
- Safety Factor: Generally applied between 1.25-1.5
1.2. Piston Diameter Determination
After the required force and operating pressure are determined, the piston diameter is calculated. As BRS PROSES, we manufacture cylinders suitable for ISO 6020/1 and ISO 6022 standards.
| Piston Diameter (mm) | Piston Area (cm²) | Force at 250 bar (kN) | Typical Application |
|---|---|---|---|
| Ø40 | 12.57 | 31.4 | Light Clamping |
| Ø63 | 31.17 | 77.9 | Medium Press Loads |
| Ø100 | 78.54 | 196.4 | Heavy Industry |
| Ø160 | 201.06 | 502.7 | Press Application |
2. Stroke Distance
Stroke distance is the total distance the piston will move. When determining the stroke, application tolerances and additional distance for position sensors must be taken into account. Buckling control is mandatory for long stroke cylinders (over 1000mm).
"Detailed cylinder selection is the foundation of the project. Small errors in diameter, stroke, and pressure calculations turn into large performance losses."
— BRS PROSES Engineering Team
3. Operating Environment Evaluation
Environment Conditions Critical
The operating environment directly affects the selection of cylinder material and seals. The following factors must be evaluated:
- Temperature Range: -20°C to +80°C standard, special seals for extreme conditions
- Corrosive Environment: Stainless steel or chrome plating required
- Dust/Dirt: Rod wiper and protective selection
- Mounting Position: Horizontal, vertical, or angled mounting requirements
4. Connection and Mounting Types
Cylinder mounting type should be selected according to the application. Most common mounting types:
- Flange Mount (MF/MP): For fixed applications
- Clevis Mount (MT/MG): Where angular movement is required
- Eye Type (MS/MH): For pivot connection
- Square Flange (MF4/MF5): Heavy load applications
5. BRS PROSES Cylinder Selection Support
As BRS PROSES, we are with you in your hydraulic cylinder selection with over 25 years of experience. Our engineering team provides:
- Free technical consulting
- Application-based cylinder calculation
- ISO and ECO series standard cylinders
- Custom design cylinder manufacturing
- Fast delivery and technical support