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Converting to

Hydra-Pneumatic Hammers

In the current environment where energy costs represent a major proportion of a company's annual expenditure the opportunity to reduce this by up to 75% is not to be missed.

The Hydra-Pneumatic hammer has been developed over the past 10 years for both open die and closed die forging, with the number of working conversions and complete hammer installations now approaching 100.

Sizes range from 1 to 16 ton in either conversions of existing air hammers or complete hammers with the quality, efficiency and reliability expected by the European forging community.

Forge Tech Services being the sole importers for Hydra-Pneumatic hammers in Europe and South Africa have both the technical and service backup needed to bring this technology to the worldwide forging industry allowing their customers to remain competitive in the world market.

The Basic Technology

Examples of converted Hydra-pneumatic Hammer Systems

Hydra-Pneumatic Single Arm (Rigby type) Open Die Forging Hammers
Hydra-Pneumatic Double Arm (Arch) Open Die Forging Hammers

Hydra-pneumatic Closed Die Forging Hammers

Pressurised hydraulic oil enters the underside of the piston lifting the hammer tup and compressing the Nitrogen that is held above the piston. Once the tup reaches the desired height the quick release oil valve is opened and the compressed nitrogen forces the tup down and imparts the blow.

Due to the flexibility offered by Nitrogen being the motive force, the hammer can use a basic form of control and utilises the original hand lever operated by the hammer driver. This gives the Hydra-Pneumatic Hammer the familiarity and easy control of an air hammer without the reliance on expensive electronics.

Cylinders



The Hydraulic unit consists of the main tank, electric motor/pump units cooling and filtration systems.

Most sizes of hammers have at least one spare motor/pump to enable easy maintenance without having to stop the hammer production

 

   

The advantages:

  • Up to 75% lower electrical power costs.
  • Increased blow energy over the original donor hammer.
  • Higher impact velocity.
  • Hammer becomes a stand alone unit.
  • The hydraulics can be stopped when not needed.
  • No compressed air system to maintain.
  • No Compressor cooling system.
  • No need to wait for air pressure to build up.
  • Blow rate equal to air hammer.
  • Interest free loans from the carbon trust
    (subject to company eligibility).
  • 12 to 18 month payback on investment.

The Savings

A typical 3 ton Rigby or arch type hammer will need 3 compressors using 380 kWh motors.

  • A Hydra-Pneumatic hammer will use 3 motors of only 75 kWh to drive the hydraulic unit.
  • When this power saving is coupled with the ability to turn the hydraulics off when not in use savings can easily reach 75% on a single hammer installation.

HYDRA-PNEUMATIC 5 TON SINGLE ARM
OPEN DIE FORGING HAMMER

Technical Data for single arm (Rigby) open die forging hammer conversion

Hammer

DY1

DY2

DY3

DY4

DY5

Weight of falling part
1000
2000
3000
4000
5000
Blow energy (Kj)
                 (Mkg)
35
60
120
140
160
3,570
6,118
12,236
14,276
16,315
Stroke (mm)
1000
1100
1200 ~1400
1450
1500
Blow rate
80
70
60
55
50
Piston rod diameter (mm)
70
80
90
90
100
Piston diameter (mm)
100
130
150
150
150
Working oil  pressure (Bar)
100 - 120
100 - 120
100 - 120
100 - 120
100 - 120
Working gas pressure (Bar)
18 – 25
20 – 25
20 – 25
20 – 25
25 – 30
Power of     (kW) electrical motors
1 X 55
2 X 75
2X 75
3 X 75
3 X 75

HYDRA-PNEUMATIC 8 TON ARCH
OPEN DIE FORGING HAMMER

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Technical Data for double arm (Arch) open die forging hammer conversion

Size of hammer

SDY1

SDY2

SDY3

SDY5

SDY8

SDY10

Weight of falling part
1000
2000
3000
5000
8000
10000
Blow energy (Kj)l
            (Mkg)
35
70
125
170
260-280
330 -380
3,570
7,100
12,740
17,335
26,510 ~
33,650~
Stroke (mm)
1000
1250
1450
1500
2250
2500
Blow rate
80
70
60
55
50
45 – 50
Piston rod diameter (mm)
70
80
100
100
125
140
Piston diameter (mm)
100
130
150
160
200
250
Working oil  pressure (Bar)
100 - 120
100 - 120
100 - 120
100 - 120
100 – 120
100 – 120
Working gas pressure (Bar)
18 – 25
20 – 25
20 – 25
25 – 30
25 – 30
25 – 30
Power of     (kW) electrical motors
1 X 55
2 X 75
3 X 75
3 X 75
5 X 75
5 X 75

HYDRA-PNEUMATIC 3 TON
CLOSED DIE FORGING HAMMER

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Technical Data for closed die forging hammer conversion

Size of hammer

MDY1

MDY2

MDY3

MDY5

SDY10

SDY16

Weight of falling part
1000
2000
3000
5000
10000
16000
Blow energy (Kj)
-----------(Mkg)
25
50
75
125
250
400
2,500
5,100
7,650
12,750
25,500
40,790
Stroke (mm)
1200
1200
1250
1300
1400
1500
Blow rate
80
70
60
60
50
40
Minimum die height (mm)
220
260
350
400
450
500
Distance between guides     (mm)
500
600
700
750
1000
1200
Power of  (kW) electrical motors
1 X 55
2 X 75
2 X 75
3 X 75
5 X 75
5 X 75