pneumatics the perfect arrangement solutions for pneumatic cylinders news busak+shamban becomes...

Trelleborg Sealing Solutions No. 1, 2007

in thegrooveThe world of seals and serviceAll Industries

Mobile Hydraulics

The pressure’s offNew Turcon® Stepseal® V

has a unique pressure reliefchannel

Sealing solutions for pneumatic cylinders

News

Busak+Shamban becomes TrelleborgSealing Solutions

A new name with anoutstanding history

The perfect arrangementPneumatics

In this edition:New solutions presented at Hannover Show 2007

contentscontents

HydraulicSealing

Materials Spotlight

Pneumatics

Aerospace

RotarySealing

Materialcompetence

Automotive

Chemical & Processing


Sanitary &Heating

HydraulicSealing

News 3

Busak+Shamban becomes Trelleborg Sealing Solutions – 4A new name with an outstanding history

The pressure’s off 6New Turcon® Stepseal® V has a unique pressure relief channel

A material matter 10Leading edge materials technology is fundamental to effective sealing

Keeping up with the grind 12Turcon® MF designed for processing needs

At the cutting edge 14Oil seals that give superior performance

The perfect arrangement 16Sealing solutions for pneumatic cylinders

All in vane 20Rotary actuators in vehicle anti-roll systems are fitted with advanced vane seals to minimize leakage

A large step in size, a giant leap in sealingtechnology 22Introducing Fleximold™, a new method for production oflarge diameter seals

A booster for processing technology 24Sealing configuration manufactured in extremely cold-resistantmaterials

Flying pistons make pressure constant 26Development project with Elster Kromschröder AG

The heart of mobile hydraulic systems 28Custom designed sealing gasket developed for Saurer-Danfoss

The whole package 30Providing not just technical solutions, but partnerships

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MAKS 2007: International Aviation andSpace SalonThe International Aviation and Space Salon, MAKS, holds the

leading position in ratings for major world aviation forums.MAKS demonstrates Russian technology and domestic

market openness to joint ventures with the use offoreign partners’ cutting-edge advances.

Held in Moscow, Russia, this year’s show will takeplace from August 21st-26th.

Katowice 2007The International Trade Fair for Mining,

Power Generation and Metallurgy inKatowice, Poland is the largest European

exhibition presenting the latest achievements ofthe heavy industry. Most companies exhibiting

represent the mining and metallurgical sectors andcome from all over the world. Visitors come from

Europe, Ukraine, Belarus, Russia, Romania, Serbia andMontenegro, India, China, Croatia, Nigeria and South Africa. This

year’s event will take place from September 11th-14th.

SEMICON West 2007SEMICON West is the largest and mostcomprehensive industry event in the UnitedStates, hosting more than 1,500 key playersin the semiconductor, FPD, MEMS, display andmicroelectronics industries. The conference,held in San Francisco, California, showcases thelatest products and technologies currently used inmanufacturing while highlighting the technologyof tomorrow. This year’s show will take place fromJuly 17th-19th. You’ll find us in South Hall,Booth 2612.

Offshore Europe 2007Offshore Europe is the largest oil & gas conference and exhibitionoutside of North America. A truly global audience of engineers,technical specialists and industry leaders gather to sourceand discuss new exploration and productiontechnology, to debate new ideas and to discoverthe solutions that will deliver sustainable oil &gas in the future. The show is held inAberdeen, Scotland from September4th-9th, and you will find us in Stand 1177.

newsnews

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Last fall, Trelleborg Sealing Solutionsrelocated and expanded its ApsleyStreet, Hudson facility to a state-of-the-art, custom-designed 29,000square foot (2,694 square meters)plant in Northboro, Massachusetts. Apart of the acquisition of Chase-Walton Elastomers, Inc. in 2005, thisfacility is focused on the aerospaceindustry. The move was necessarybecause of our increasing business inthe airframe market.

The acquisition of Chase-Waltonallowed Trelleborg Sealing Solutionsto enlarge its portfolio of products,especially in the aerospace, medicaltechnology and biotech industries.The increased manufacturingcapabilities brought about by theacquisit ion, along with thisexpansion, means we can betterfulfill our increasing volume oforders from our already strongcustomer base.

The Northboro facility employs 126people, and the majority of thesework in production. The substantialinvestment in the new building andequipment in Northboro supportsour abilities in state-of-the-artmanufacturing of high-qualityprecision seals and our highly-skilled

team of design, process, and qualitycontrol engineers. “This is only the beginning,” saidMark Barnes, airframe productmanager for Trelleborg SealingSolutions Americas, “The move hasincreased our facility’s capacity by 20percent and leaves the door open forfuture expansion, with 25,000 squarefeet of available space. We are verypositive about the future growth ofour new plant.”

Expanding to Fit Greater capacity forproduction of airframecomponents with openingof new leading edge USmanufacturing facility

Trelleborg Sealing Solutions is participating in a number ofexhibitions worldwide. Why not come and visit us!

Exhibiting around the world

newsnews

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Busak+Shamban has been part of Trelleborg Group, withwhom we share a foundation in polymer expertise, sinceour acquisition in October 1, 2003. With a pedigree goingback over 50 years, the marketing arm continued tooperate under the existing Busak+Shamban brand, whilethe manufacturing facilities adopted the Trelleborg name.Effective from April 2, 2007, to consolidate the group’sbrand strategy, Busak+Shamban has changed our name toTrelleborg Sealing Solutions.

“The transfer will be seamless,” says Claus Barsøe, Presidentof the Trelleborg Sealing Solutions business area. “We feelthis change will unify our total brand offering, emphasizingthat our marketing companies and manufacturing facilitiesrun as a cohesive unit. The quality of support and service wegive to our customers will not be affected. In fact, it canonly be enhanced by our future plans.

“Our business is core within the Trelleborg Group. Anexciting time ahead, the name change heralds moresignificant investment in our business area. This will furtherstrengthen our position as one of the world’s leadingdevelopers, manufacturers and suppliers of sealingsolutions to aerospace, industrial and automotive marketsglobally.”

Busak+Shamban becomesTrelleborg Sealing Solutions

Busak+Shamban operated as the global sales andmarketing arm of TrelleborgSealing Solutions. To consolidate our brandstrategy, Busak+Shamban is now Trelleborg SealingSolutions, effective April 2,2007.

A new name with an outstanding history

Trelleborg Sealing SolutionsIn the groove - All Industries, No. 1, 2007© Trelleborg AB, 2007. All rights reserved® All trademarks are the property of Trelleborg AB.The turqouise color is a registered trademark ofTrelleborg AB.

Editorial Office:Trelleborg Sealing Solutions Germany GmbHHandwerkstraße 5-7, 70565 Stuttgart, Germany Email: [email protected] Web: www.tss.trelleborg.com

Editorial team:Heather Castleman, Donna Guinivan, Whitney Killip,Wendy Sack, Robert Zahiri

Responsible under German Press Law: Robert ZahiriGraphic Arts: dialogart, Stuttgart, GermanyPrinting: W. Kohlhammer, Stuttgart, Germany

Disclaimer: The information in this magazine isintended to be for general reference purposes only andis not intended to be a specific recommendation forany individual application. The application limits forpressure, temperature, speed and media given aremaximum values determined in laboratory conditions.In application, due to the interaction of operatingparameters, maximum values may not be achieved. It isvital therefore, that customers satisfy themselves as tothe suitability of product and material for each of theirindividual applications. Any reliance on information is therefore at the user’sown risk. While every effort is made to ensure theaccuracy of information contained herewith, TrelleborgSealing Solutions cannot warrant the accuracy orcompleteness of information. For exceptional operating conditions, please contactyour Trelleborg Sealing Solutions representative.

Fast facts about Trelleborg group

Trelleborg is a global industrial group whose leadingpositions are based on advanced polymer technology andin-depth applications know-how. Trelleborg develops high-performance solutions that seal, damp and protect indemanding industrial environments. The Trelleborg Grouphas annual sales of approximately SEK 27 billion (2.9 billionEuros, 3.8 billion US Dollars), with about 23,000 employeesin 40 countries. The Group comprises four business areas:Trelleborg Engineered Systems, Trelleborg Automotive,Trelleborg Sealing Solutions and Trelleborg Wheel Systems.

www.trelleborg.com

Fast facts about Trelleborg Sealing Solutions

Trelleborg Sealing Solutions is one of the world’s leadingdevelopers, manufacturers and suppliers of precision seals.We support our aerospace, industrial and automotivecustomers through 30 production facilities and more than40 marketing companies globally. Within our portfolio aresome of the longest established sealing brands, includingDowty, Forsheda, Palmer Chenard, Shamban, Skega andStefa along with a large number of proprietary productsand materials such as Turcon®, Zurcon®, Orkot®, Isolast®,Stepseal®, and Wills Rings®.

www.tss.trelleborg.com

US seal company HCRD acquired Trelleborg Group, through the Trelleborg Sealing Solutions businessarea, has acquired the operations of precision bearing and sealingdevices company Hydro-Components Research & DevelopmentCorporation (HCRD). The company employs a total of approximately 80people and has annual sales of about SEK 50 million (over $7 millionUSD). It is a privately owned company based in Streamwood, Illinois,USA.

HCRD, which manufactures high-precision components, focusesspecifically on large diameter seals and bearings. These products areused primarily in applications involving heavy-duty cylinders such asshock absorbers for earth moving equipment, dumpers and diggers.

“HCRD’s technology and products are at the leading edge ofdevelopment in the company’s area of focus and will make anextremely valuable contribution to us,” says Claus Barsøe, business areapresident for Trelleborg Sealing Solutions. “The products fit in ideallywith our current portfolio, will expand our offering and enable us togrow more rapidly in North America, within the segment for heavyduty vehicles. The acquisitions also offer distinct process andorganizational synergies.”

To find out more about this acquisition - take a look at HCRD’s website,http://www.hcrd.com/ .

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Hydraulic Sealing

Seals in tandem arrangements are commonlyused in hydraulic cylinders to optimize sealingintegrity. At the one side they keep lubricantsin, while on the other, external media is keptout. This was first made possible with Turcon®

Stepseal®. This double-acting tandem sealconfiguration was a major advance in fluidpower technology, eliminating the build-upof disruptive intermediate pressures betweenseals. Always a major problem for engineers,the pressure causes loss of operatingefficiency, resulting in destruction of seals andleakage.

Though configurations that use Turcon®

Stepseal® are usually effective, in somedesigns, pressure can still build up betweentwo seals. Based on their experience inhydraulic applications, engineers at TrelleborgSealing Solutions looked for an even more

effective geometry for these exceptionalsituations. The result is Turcon® Stepseal® V,which incorporates a unique pressure reliefvalve. This patented technology stops anypressure from being trapped between seals,even in the most difficult arrangements.

The pressure’s

offNew Turcon® Stepseal® Vhas a unique pressurerelief channel

A problem on some tandem seal arrangements used in hydraulic cylinders is pressure build-upbetween the seals. Trelleborg Sealing Solutionsintroduces Turcon® Stepseal® V to prevent this from happening.

Patented technology extends seal life

New solution presented at Hannover Show 2007!

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Elastomer O-Ring• High flexibility to satisfy hardware tolerances and movement• Elastomer materials available to meet a wide variety of

service conditions• Pressure relief valve function

Patented hydrostatic pressure relief channel• Prevents pressure trap between seals under all service conditions• Prolongs life of sealing system

Contoured rear chamfer for hydrodynamic back-pumping• Improved back-pumping of residual oil film for increased

sealing efficiency• Increased radial clearance

Notch for pressure regulation• Ensures rapid pressure actuation and pressure balancing

under all service conditions

Stabilizing edge• Prevents seal deformation under the most demanding

service conditions• Increases assembly robustness by protecting seal face during

insertion of the rod

Turcon® and Zurcon® materials• Low friction, no stick-slip• High sealing efficiency and long service life• Meets demanding service conditions• High flexibility for easy installation

Machined valve groove• Ensures precise opening and closing of the relief channel• Provides robust performance of the relief function

independent of hardware deflection

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Stepseal® V is manufactured from ourproprietary PTFE based material,Turcon®. This offers a low coefficientof friction and performs over a widerange of operating temperatures. Ithas excellent wear resistance andcompatibility with chemicals.

In hydraulic cylinders, used in everythingfrom earth moving machinery to liftingplatforms in the toughest workingenvironments, the requirements forsealing are varied and difficult. Theapplications are dynamic, often operatingat high speeds and significant pressures. A

single seal is rarely a good enoughsolution and in most cases a configurationof seals is required. Typically, a cylinderwill include between three and fivedifferent dynamic seal and scraper types,some in tandem arrangement.

Tough seals for tough environments

Turcon®: Exceptional material performance


For more information onTurcon® Stepseal® V, visit

To download the catalog,go to the Download Area.

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Hydraulic Sealing

Turcon® Stepseal® V: Advantages and benefits

High static and dynamic sealingeffect

Available for bore diameters up to 2700 mm (8’ 10’’)

Operational at pressures up to 80 MPa (800 bar,11600 psi)

Operational at speeds up to 15 m/s (49 ft/sec) withreciprocating movements, frequency up to 5 Hz

Operating temperatures of -45°C to 200°C (-49°F to 392°F)

Very good extrusion resistance, tosuit wide hardware clearances

Low friction, increasingperformance and working life

Stick-slip-free starting, no stickingeven after shut down

High abrasion resistance,maximum operational reliability

Excellent resistance to chemicals

Simple installation without sealedge deformation

Available for rod diameters up to 2600 mm (8’ 6’’)

Suited to mineral oil-based hydraulic fluids, flameretardant hydraulic fluids, environmentally safehydraulic fluids (bio-oils), water and other media

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Materials Spotlight

On the outside, one seal may appear to bethe same as the other. But the technologybehind their material means that one typecan function very differently from another.Making sure the compounds meet industryneeds means that seals can be matched to aspecific application, optimizing performance.

Leading edge materials technology is fundamental to effective sealing

A material ma

Why are more sealing materials required?

For compatibility with new contact media

To comply with more stringent regulations

Provision of a solution to a customer’sspecific problem

To withstand increased temperature in anapplication

For improvement in performance to extendseal life

Europe StuttgartHelsingorAshchurchBridgewaterMalta

USA Fort Wayne

Asia TokyoShanghai

tter

Systematic development ofmaterials based ontechnological expertise

Trelleborg Sealing Solutions has over 2,000proprietary compounds to our name. That’smore than any other seal developer andmanufacturer. Thousands of hours ofresearch and unrivalled years of experiencecombine to make our sealing formulationssuccessful.

“We invest a substantial amount of resourcesevery year in development of new sealingmaterials,” says Nils Kohlhase, director,research and development Europe. “Ourlaboratories for mixing and testing aresituated globally. We gather ideas fordevelopment projects continuously throughour Innovation Management Process. To dothis we listen to our customers, segmentexperts, sales people and engineers.”

New compounds reflectlatest industry needs

Continuous material evolution is importantas the demands of different industries areconstantly changing. Even though the rangefrom Trelleborg Sealing Solutions mayappear to fulfill all requirements, newvariations are necessary to meet the latestchallenges.

“There are many reasons why we needto add materials . Changing marketrequirements are always a key focus forus,” continues Kohlhase. “In the aerospaceindustry or the fluid power sector we maybe faced with newly introduced fuels ordifferent temperature requirements. It ispossible that one of our existing compoundsis suitable. If not, then priority is put oncreating one that will be effective. Thisensures we can continue to meet ourcustomers’ needs as quickly as possible.”

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Our global research anddevelopment centers arelocated in:

Trelleborg Sealing Solutions isconstantly developing newmaterials to meet the latestcustomer requirements. Hereare some examples.

Turcon® M03PTFE based material developed in response tothe needs of hybrid engines. Engineered toprovide excellent sealing capabilities alongwith extremely low gas permeation.Zurcon® technologyA range of improved polyurethane materials

has been developed to meet the demandingrequirements of pneumatic applications. Theygive better friction characteristics and abrasionresistance.

Ozone resistant NBR These NBR compounds specifically meet theneeds of fluid power customers who pre-assemble components with O-Rings in anelongated state. Superior ozone resistanceprevents seals cracking.

Material competence

Keeping up with the grindYou can’t compare the professional coffee machines manufactured byWMF to those you’ll find in the average home. Their machines areengineered to brew up to 300 cups of coffee per hour. That means eachcomponent must be of the highest quality and durability. The samerobustness is required from the seals that Trelleborg Sealing Solutionssupplies for these appliances.

In WMF coffee machines, the standard non-abrasive plastic internal parts of domestic models are replaced withmetal. Not only must seals be able to withstand movement

against these harder counter surfaces, they must also stand up toheat, acid, pressure, cleaning media and abrasive coffee grounds.

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The demands on seals in the WMF coffee machines are high.They need to have:

To meet all these requirements a seal was specified in Turcon® MF, our proprietary PTFE based material specificallydesigned for food, beverage and pharmaceutical processing.A modified Stepseal® design was selected, engineered toendure this intensely dynamic environment.

• Excellent friction characteristicsFor movement against the equipment’s metal counter surfaces

• Exceptional wear resistanceTo withstand abrasion from ground coffee beans

• Compatibility with process mediaIncluding acids in coffee, fats in milk and the aggressive chemicals in cleaning regimes

• Capability to operate in pressureBoiling water is forced through the coffee grounds at up to 16 bar (232psi)

• Outstanding lifeTo stand up to brewing of at least 100,000 cups of coffee

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Turcon® MF designed for processing needs

Based on ultra-clean technology, these compounds aremanufactured from high-purity PTFE grades andadditives. Their smooth finish, with high gloss and lowporosity, avoids the risk of contamination buildup andreduces particle shedding. Each batch of MF material ismanufactured using virgin material only and issued witha certificate of conformity.

Our range of Turcon® based PTFE materials offers:

From cappuccino to latte macchiato, WMF hastechnologically advanced machines to make them all. Theworld leader in manufacturing of professional coffeemakers, their equipment is heavy duty and designed tomeet caterers’ needs.

In the WMF bistro range of machines, coffee is freshlyground. A piston presses these grounds into a cylinder, atthe bottom of which is a metal sieve. To make the coffee,boiling water is jetted through the cylinder with a 70 mm(2.7 in) stroke of the piston at a pressure of 16 bar(232psi). The sieve then swings down and the pistonpushes the used coffee grounds out of the cylinder intoa collecting tray. This process is repeated for every singlecup of coffee, up to 300 times per hour.

A modified Stepseal® manufactured in Turcon® MF,supplied by Trelleborg Sealing Solutions, is used forsealing this piston. It is proving to offer extended life inthis harsh processing environment.

Making the perfect cup of coffee… 300 times per hour

WMF... coffee wakes up the world

Temperature resistance from –253°C (–423°F) to +260°C (500°F)

Almost universal chemical compatibility

Outstanding low long-term compression set characteristics

High wear resistance

Minimal creep and permeation

Surface finish minimizes contamination risk

Materials perform well in a broad range of chemicalmedia including organic and inorganic oxides, acids, alkalis,amines, esters and steam

Materials compliant to FDA 21 CFR177.1550, 3-A, USP Class VI and sanitary standards

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Rotary Sealing

At the cutting edgeOil seals that give superior performance

With their cut edge, oil sealsmanufactured by TrelleborgSealing Solutions eliminatepotential leakage problems. Thisgives superior performancecompared with molded lips, andcost-effective supply is possiblethrough our global productionsites.

Oil seals: The facts

Oil seals are made up of an elastomeric diaphragmshaped in a lip form and reinforced with a co-

vulcanized metal insert. The sealing lip is energized witha garter spring, allowing them to operate at rotating shaft

speeds up to 15 m/s (49 ft/s).

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For more information onrotary seals, visit

To download the catalog,go to the Download Area.To search for specificparts, visit the ElectronicCatalog.

A pioneer in oil seals

Trelleborg Sealing Solutions is one ofthe pioneers of oil seals, supplyingthem since the 1950s. Over the yearscompetition grew and we saw othersuppliers lowering prices by moldingthe lip on oil seals, removing the costlycutting operation from themanufacturing process. However,critical to the oil seal’s operation, is thatits lip fits as closely as possible withinthe sealing environment. TrelleborgSealing Solutions was not willing toreduce the sealing integrity of ourproduct. So we decided to find out if anoil seal with a molded lip could be aseffective as one with a cut lip.

Molded lips are not aseffective as cut lips

To analyze this, extensive endurancetests were undertaken by TrelleborgSealing Solutions engineers to see if itwas possible to produce a molded lipthat could fulfill the performancedemands for oil seals. After these,

lasting thousands of hours, theyconcluded that molding could notprovide sufficient sealing integrity. Thebest method of production in themajority of cases was to continue to cutthe edge, especially for standard seals.

Cost-effective supply fromlower cost countries

“We would not change ourmanufacturing methods, if this gaveinferior performance,” says FrankKleeman, product manager, oil seals,“but we still wanted to meet our keycustomers’ expectations for cost-effective supply of these products.One advantage the Trelleborg SealingSolutions global network gives us isthat we can move manufacturing tolower cost countries within the group.We decided to do this but determinednot to compromise production qualityin any way. Engineers from theoriginal manufacturing sites wereinvolved in and oversaw the transferprocess to make it seamless.”

Excellent performancefrom a wide material range

The superior performance of theTrelleborg Sealing Solutions oil sealdoes not rely upon its method ofproduction alone but also materialstechnology and product design.We offer a choice of more than100 market-leading proprietarycompounds specifically developed foroil seals. The materials provideexcellent performance propertiesincluding exceptional dispersion andsuperior aging resistance in air orfluids. They are also supplied instandard designs and customgeometries. This means that sealinglife can be optimized, as sealcharacterist ics can be preciselymatched to operational parameters.

The sealing lip design for TrelleborgSealing Solutions oil seals is state-of-the-art and based on many years ofexperience in a wide range ofapplication fields.

Extensive testing provesTrelleborg Sealing Solutions oilseals are superior

Tests were carried out on oil seals toASTM and ISO standards in air,water, oil, grease and other fluidsat various temperatures andtime periods. Trelleborg SealingSolutions oil seals achieved onaverage a 6,000 hour sealing lifebefore reaching a specified leakagelimit, with a considerable number ofseals exceeding 10,000 hours. This wassignificantly higher than the sealing life ofthe majority of other products tested.

The dilemma: A molded or cut edge

The sealing edge of oil seals can either beready molded or trimmed by mechanicalcutting. The latter option requires anextra operation, which many suppliersdeem too costly. Instead they rely on amolded sealing lip being sufficientlyclose-fitting. However, as a molded edge

is rounded, it can never work as well as acut edge. In addition, air caught in the

compound during the molding processcreates blisters. If one of these is near the

sealing edge, it weakens the lip and is potentiallyan area of leakage.

The sealing lip design for TrelleborgSealing Solutions oil seals is state-

of-the-art and based on many yearsof experience in a wide range of

application fields.

Rubbersection at thecontact area

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Pneumatics

The perfectarrangement

Sealing solutions forpneumatic cylinders

Excellent leakage control from seals suppliedby Trelleborg Sealing Solutions is expected byour customers manufacturing pneumaticcylinders. There is an amazing amount oftechnology behind the sealing arrangementswe recommend, and they are based on yearsof experience and research.

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Optimized sealingperformance

So maintenance can be minimized,pneumatic cylinder manufacturersdemand long life from seals. It’s noeasy job to provide products that canachieve this. To ensure integrity theymust demonstrate excellent frictioncharacteristics and wear resistanceagainst their housing. A single seal israrely sufficient and special lydesigned arrangements must keeplubricant within the housing, while also excluding media such as dust anddirt.

Trelleborg Sealing Solutions has beendesigning and developing sealingconfigurations for pneumaticcylinders for over 50 years. Thoughsome of the geometries andarrangements we recommend maylook complex, they are based onsubstantial material expertise andtechnology. Never relying onguesswork, product recommendationsare proven in extensive long-termtests to ensure optimizedperformance.

FKM materials specially designed for pneumatics

Our fluoroelastomer (FKM) materialsdeveloped specifically for pneumaticapplications offer a high temperaturesolution, operating up to 150°C(302°F). With good thermosettingbehavior, they show resistance toaging and ozone. VC6B4 is FKM alonewhile VCBVR is an FKM and metalcombination.


Polyurethane and polyethelene-basedmaterials are the usual choice for pneumaticcylinder sealing. These offer excellent frictionperformance, vital in these applications, inaddition to almost universal chemicalcompatibility. All the materials developed byTrelleborg Sealing Solutions are designed tooptimize these characteristics along withproviding exceptional abrasion resistance.

The perfect product choiceA wide choice of seals and scrapers ensures very specific pneumatic sealing demands can be met.

ARUP U-Shaped single-acting rod seal

The pneumatic engineeredplastic selection

AWBB Wiper Specially designed for guide units with linearball bearings. Minimal pre-load avoids anynegative influence on sliding behavior.

AICM Seal Specially designed for pneumatic cushioningwhere there are high pressure peaks. Afterchange of pressure direction an integratedcheck valve function ensures pressureapplication on the full piston surface.

AIAS Cushioning seal like AICM but capable of fittinginto existing O-Ring grooves.

GM500 Static seal comprised of an elastomer lipbonded to a metal washer. Designed to seal connections and couplingswithin pneumatic cylinders.


For more information on pneumatic seals, visit

To download the catalog,go to the Download Area.

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PneumaticsNew Zurcon® high-performance polyurethane materials

Zurcon® Z20 94 Shore A with operating temperature up to 110°C (230°F)

Zurcon® Z22 Low temperature 94 Shore A material capable of operating down to -45°C (-49°F)

Zurcon® Z24 94 Shore A with enhanced hydrolysis resistance

Zurcon® Z30 83 Shore A with operating temperature up to 85°C (185°F)

Zurcon® Z32 83 Shore A combining low temperature operation down to -50°C (-58°F) with enhanced hydrolysis resistance

Zurcon® Z80

WU9E1 Standard polyurethane material with fair performance level

52 Shore D ultra high molecular weight polyethylene which gives high abrasion resistanceeven under poor lubrication conditions. FDA compliance makes it suitable inpharmaceutical, food and beverage processing.

ARS Combined seal and scraper.Suitable for single assembly in standard grooves in higher temperature applications.

AWNS Lip seal with sealing lip and scraper lip.Ideal for small installation spaces.

AWSD Like AWNS but with the capability ofinstallation in small diameters.

ARAA Rod seal-scraper with integrated fixingcapability.

ARAN Asymmetric lip seal with sealing lip and scraper.Excellent protection against dirt ingress. Fast installation, automatic or manual.

AWSW Single-acting scraper for use with separate rodseal. Special lip design maintains rod lubrication.

ARV Asymmetric Variseal® with spring-energizedsealing and scraper lip. Suitable for high speed applications with poorlubrication. Excellent protection against dirtingress.

ARG Double-acting Glyd Ring® rod seal comprised ofa slipper seal and energizing O-Ring. Specially designed for low friction applicationswith small installation space.

DRV4 Static sealing element consists of two injection-molded parts. Dimensions conform to ISO 16030and they are ideal for automatic mounting,with no installation space required.

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APDE Single-acting piston seal, double-acting whenused back-to-back. Suitable for cylinders with pneumaticcushioning.

APDF Standard piston seal with dimensionsaccording to ISO 3320 that has excellentendurance test results and stick-slipcharacteristics. Suitable for use in end positioned dampedcylinders and exhaust throttles.

APDG Similar characteristics to APDF and also idealfor small space installations.

APDS U-Shaped single-acting piston seal, double-acting when used back-to-back. Demonstratessuperior friction characteristics and improvedbreak off pressure. Recommended for returnspring cylinders where better piston guidanceis needed. Suitable for cylinders with pneumaticcushioning.

APMP Single-acting piston seal, double-acting whenused back-to-back. Has integrated guidingelement and buffer for mechanical cushioning.Suitable for short stroke cylinders or magneticpistons.

APG Double-acting Glyd Ring® comprised of slipperseal and energizing O-Ring for piston sealing.Ideal for small space installations and suitablefor cylinders with pneumatic cushioning.

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Automotive

All invane

Trelleborg Sealing Solutions suppliesadvanced vane seals to a majorautomotive component manufacturer,ZF Sachs, for a rotary vane actuator usedin their active roll stabilization system.The razor sharp edges of these stampedsintered plates ensure maximum sealingintegrity between fluid chambers thatcontrol actuation.

Rotary actuators invehicle anti-roll systems

manufactured by ZFSachs are fitted with

advanced vane seals tominimize leakage

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ZF Sachs, a major manufacturer of suspension systems,approached Trelleborg Sealing Solutions when they weredeveloping their innovative active roll stabilization system.Movement was to be controlled by a rotary vane actuator,and they needed vane seals that could minimize leakageacross compartments. However, they also wanted them inhigh volume and supplied as cost-effectively as possible.

Razor sharp vane seals proved in application

Effective sealing within rotary vane actuators is achallenge, as the shape to be sealed is rectangular and thefour corners of the seals must be razor-sharp. If the seal isnot perfect, liquid can leak from one working space toanother, deteriorating performance of the suspensionsystem.

The usual method of producing these rectangular seals is bymilling, but this is costly and significant volumes can bedifficult to achieve. So, engineers at Trelleborg SealingSolutions decided to look for a different process to reduceproduction costs and increase yield. Their alternative wasto stamp sintered plates of Turcon® PTFE based materialto the shape of the seal. Now used for several years byZF Sachs, sealing integrity is proven. They operateeffectively at temperature extremes, ranging from - 40°C(-40°F) to well above +100°C (212°F), and at pressureexceeding 150 bar (2175 psi).

What are rotary vane actuators?

Rotary actuators are used to pivot ajoint and are an alternative toconventional cyl inder mounting.Unlike these, they are not limited to a90-degree pivot but can achieve arclengths of 180, 360, 720 degrees ormore, depending on the configuration.

There are many types of rotaryactuators but in a vane actuator, arotor replaces the piston, whichoperates within l inear hydrauliccylinders. This has one, two, three ormore vanes attached to it. Whendifferential fluid pressure is appliedto the working chambers, theactuator turns.

Innovative manufacturing of vaneseals takes place at TrelleborgSealing Solutions Helsingør. Theseproducts are now providing distinctcost and performance benefits tocustomers, extending the potentialapplications for rotary vaneactuators in many different sectorsof industry.

Introducing Fleximold™, our newproprietary method for production of

large diameter seals

Features and Benefits

• Capable of producing any diameterabove 500 mm/ 20 inches

• Full visual and dimensional productintegrity

• High quality, tight tolerances

• Performance capabilities matchingmolded O-Rings

• Elimination of leakage risksassociated with spliced O-Rings

• No tooling charges for standard crosssections

• Available in Isolast®

perfluoroelastomer and a wide rangeof other elastomers

Product availability:

Sizes:

• Recommended for diameters > 500 mm / 20 inches Cross Sections:

• All standard cross sections availablewithout purchase of dedicated tool

• Larger and special size cross sectionsavailable upon request

• Non-standard seal profiles availableupon request

A large step in size, a giantleap in sealing

technology

International Cross Reference Standard Section, Section,

mm inches

Metric 3.00 0.118JIS B 2401 3.10 0.122Metric/JIS 3.50 0.138AS-568 3.53 0.139JIS B 2401 3.55 0.140Metric 4.00 0.157Metric 5.00 0.197JIS B 2401 5.30 0.209AS-568 5.34 0.210Metric/JIS 5.70 0.224AS-568 6.99 0.275JIS B 2401 7.00 0.275Metric 8.00 0.315JIS B 2401 8.40 0.330Metric 10.00 0.394

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Trelleborg Sealing Solutionsintroduces FlexiMold™, its newlydeveloped proprietary technologyfor the manufacture of high precision,large diameter O-Rings and otherseal profiles.

Better quality with no tooling costs

Large O-Rings and seals areused across all process industriesincluding Chemical and Hydrocarbon,Pharmaceutical, Food and Beverage.The conventional method ofproducing large diameter O-Rings andseals is by splicing extruded cord.However, inherent in this method of

fabrication is a weakness at thejoin, along with poor surface finishand difficulty in achieving tighttolerances. Alternatively, a dedicatedtool is required with its associatedhigh investment and long leadtime.

FlexiMold™ is a new proprietarytechnology specifically developedby Trelleborg Sealing Solutions formanufacture of large O-Rings andother seal profiles. With it, productionof giant high quality seals is possiblewithout the leadtime and costassociated with dedicated tooling.The FlexiMold™ process eliminates therisks associated with spliced O-Rings,ensuring the full visual, dimensionaland functional integrity of a moldedseal.

Examples of Applications

• Flat Panel Display

• Large Cover Seals

• Vessels

• Electrolysers

• Filters

• Power Generation

• Other large processing equipment

Service:

• O-Rings supplied to standards ISO 3601-1,AS568 and JIS B 2401

• Product inspected to zero defect policy

• Parts packaged and labeled individually

• Washed and packed in Class 100Cleanroom if required

• Express delivery service available

Materials:

• Isolast® perfluoroelastomer (FFKM)

• ResifluorTM High Performance FluorinatedElastomers

• Fluorocarbon (FKM)

• Ethylene Propylene (EPDM)

• Acrylonitrile Butadiene Rubber (HNBR)

• FDA, USP Class IV approved compounds

• Explosive Decompression Resistant (EDR)materials

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Development Partnerships -Chemical & Processing

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A booster for processing A sealing configuration manufactured in extremely cold-resistantmaterials by Trelleborg Sealing Solutions helps Norgren to improve the low temperature performance of their valves.

With a stroke size of only 6mm (.2in), thebooster, with a nominal value of DN 25,allows a flow rate of up to 14,200 l/min(3,748 gal/min).


The booster as well asother seals needs to meetthe standards in line withSIL according to IEC 61508.

Large ball and butterfly valves are used in thechemical and process industries as well as in oiland gas production. They are usually operatedby compressed air but such a large volume flowis required, that it is not possible to trigger themdirectly. Even a pilot valve is not sufficient toclose the shut-off device quickly enough in thecase of an emergency. This is why booster valvesare placed between these large ball or butterflyvalves and their pilot valves.

Norgren produces these booster valves, their80300 line is a typical example. They need tooperate at extremely low temperatures. Ori-ginally, Norgren’s booster models could onlywithstand temperatures to –40°C (-40°F), but themarket increasingly demanded even better coldresistance down to –55°C (-67°F). Responding tothese demands, Norgren improved the low tem-perature performance of its 80300 line. In orderto help do this, they have specified new boosterseals from Trelleborg Sealing Solutions, madefrom extremely cold-resistant materials.

All three of the seal materials selected cover atemperature range of –55°C to +80°C (-67°F to+176°F). The Variseal® offers good friction per-formance and supports a quick response time forthe booster. Its optimized design allows snap-inproduction for speedy assembly in the manufac-turing plant or in service. Turcon® T19 with aType H spring was specified for the Variseal®. Thiswas so it would work effectively with its matingsurfaces, be compatible with the housing madeof high-grade steel and operate in the requiredtemperature range.

Lower temperature performancewas demanded of booster valves

Innovative seals and materialsmeet Norgren’s requirements

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About booster valves

Booster valves are poppet valves, which canincrease controlled airflow by 250 to 500 times.These valves can provide up to 14,200 liter/min(3,748 gal/min) of compressed air with 0 to 1.2MPa (0 to 174 psi) per minute respectively (basedupon the nominal value DN 25).

They are used in the operation of huge shut-offdevices in the chemical and process industry, aswell as in petrochemical and gas manufacturingplants and machines. Norgren produces them inhigh-grade steel and they are validated to SIL(Safety Integrity Level) according to standard IEC61508.

technology

The sealing configuration

consists of three types of seal:

• Turcon® Variseal®

• Sealing disc made of Zurcon® Z22

• O-Rings made of cold resistant NBR N7T40

Flying pistons makepressure constant

Development Partnerships - Sanitary & Heating

Both the seals, as well as the metal armature plates, are mounted to the flying pistons and machined to meet extremely tight tolerances.

Trelleborg Sealing Solutions was involved in development of a sealing arrangement forflying pistons in the compact gas control systems manufactured by Elster KromschröderAG. This involves a material specially engineered for the application and an innovativemanufacturing process to achieve tight tolerances.

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Elster Kromschröder AG safeguarding, measuring and controlling gases

Elster Kromschröder AG is a leading producer of filters,pressure regulators, valves and butterfly valves, pressureswitches and combination controls. They also supply gasburners and pilot burners, as well as devices for monitoring,controlling and automation. Their high quality components,

intelligent system solutions and various services make itpossible for users of their products to use natural gaseconomically, safely and in an environmentally-friendly way.This helps save resources in every respect, when generatingand using heat for process and heating purposes.


Seals for flying pistons are manufactured froma special Turcon® PTFE based compoundX9820. This is an aromatic polymerincorporating a lubricant filler.

Elster Kromschröder AG compact gas control systems providethe solution to the problem of varying pressure in naturalgas supply networks. Gas pressure, which is produced in anarmature by a linear compressor, operates the control andregulating valves and a constant initial pressure is maintained.This is crucial for steady combustion with low emissions.

In these designs, this is achieved without the use of magnetvalves, the standard option, even when there is a high inletpressure. Instead, a flying aluminum piston oscillates betweenelectronic magnetic Dewars to power the linear compressor.It operates like an axial piston pump, only without thepiston rod, with an alternating current frequency of 50times per second.

Within these flying aluminum pistons, sealing rings used tobe stuck to the cylinder surface without any grooves forthem to fit in. However, this practice was very time consumingand complicated both in the preparation of the pistoncylinders as well as in the adhesion process.

A development project between Trelleborg Sealing Solutionsand Elster Kromschröder was undertaken with the objectiveof finding an alternative sealing arrangement for the flyingpiston. The seals had to be soft enough to protect the hardmaterial coated cylinders from premature wear. At thesame time, they needed to be resistant over a service life often years. That means capable of enduring 5.4 billioninstances of friction with the piston wall.

“To make sure we could provide the required seal life in thislevel of friction we decided to develop a material specificallyfor the application,” says Stephan Brändle, one of the Trelleborg Sealing Solutions sales team involved with thiscustomer. “Based on our vast experience of compound formulation, the proposed solution was a Turcon® PTFEbased material with lubrication incorporated into it.

“The flying piston was redesigned to include two sealinggrooves into which the Turcon® PTFE with an O-Ring energizeris fitted. An innovative manufacturing process then involvesus machining metal armature plates mounted to the pistonstogether with the seal bearing surfaces. This ensures thatthe seals meet the required extremely tight tolerance of.0007in (.02mm). The machining process also balances outany measurement deviation of the cylinders.”

Elster Kromschröder AG has adopted this sealing design for its compact gas control systems. It is now proving toachieve the required integrity in this demanding dynamicenvironment.

In the flying piston, the bearing surface rubs the pistonwall 5.4 billion times over a ten-year period, oscillating

15,768,000,000 times. That’s equivalent to it traveling113,530 kilometers (70,388 miles).

Gas pressure is regulated by flying pistonsin compact gas control systems oscillatingat a frequency of 50 times per second

Seals have to give a service life of 10years, that means withstanding 5.4billion movements against the piston wall

Elster Kromschröder AG compact gas control systems contain flying pistons to regulate gas pressure.

Trelleborg Sealing Solutions provided a unique custom made sealing solution for these.

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A unique lubricated material andinnovative manufacturing processprovide sealing integrity

Development Partnerships -Hydraulic Sealing

The heart of mobile Trelleborg Sealing Solutions worked with Sauer-Danfoss todevelop a custom designed sealing gasket for their new H1range of hydrostatic pumps.

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Sauer-Danfoss calls its new H1 pump line the heart of ahydraulic drive. These closed circuit variable displacementaxial piston pumps are very powerful, quiet and compact. Itis these attributes that make them ideal for use in mobilehydraulic engineering, especially when users increasinglydemand energy efficient and low maintenance technology.Developed with the help of Finite Element Analysis (FEA), acustom designed sealing gasket from Trelleborg SealingSolutions is contributing to the new pump range’s effectiveness.

The “heart” is packed with high-tech components; thisincludes its custom designed sealing gaskets. System developers at Sauer-Danfoss worked closely with the Trelleborg Sealing Solutions team to engineer these, usingadvanced 3D CAD systems. The process of doing this included several steps utilizing FEA simulation to optimizethe geometry of the gasket.

FEA was used to optimize seal performance

hydraulic systems

The result is a complex gasket with a profile that allows itto fit perfectly into its housing. With operating pressuresup to 7 MPa (1,015psi) and a sealing gap of 0.3 mm (0.01in),it keeps contact pressure at a low level, provides exceptionally high wear resistance and very good mediacompatibility. Injection molded in polyurethane Zurcon® Z20,this material met all of the needs of Sauer-Danfoss. Thesewere temperature resistance from –40°C to +100°C (–40°Fto +212°F), extrusion stability, very good media compatibi-lity, the ability to maintain its shape and low shrinkage.

FEA was an integral component of the success of this project.We were able to engineer the sealing material and developthe profile in parallel. The use of FEA analysis shorteneddevelopment time and gave the flexibility to optimize theseal design in a virtual environment, helping ensure thesuccess of the H1.

Seals on the Sauer-Danfoss new H1 axial piston variable displacement pumps range need to cope withpressures up to 480 bar (6,960psi) and temperatures of–40°C to +100°C (–40°F to +212°F).

Advanced analysis resulted in a sealinggasket to meet the needs of Sauer-Danfoss

Design in a virtual environmentshortened development time

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H1 – the new generation of hydrostatics

For more than 40 years, Sauer-Danfoss has beendeveloping state-of-the-art components and systemsfor mobile machinery used in off-highway operationsaround the world. All that experience has beenchanneled into the new, unique H1 family of single andtandem pumps.

H1 is a range of servo-controlled hydrostatic single andtandem pumps, developed with a clear vision oftomorrow’s world. It is designed for quality andreliability and offers expanded functionality, greatertotal efficiency and easy installation. Working quietlyinside, it is at the heart of tomorrow’s mobilemachinery.

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Aerospace

Customer Focus- a complete approach

Trelleborg Sealing Solutions Americas has adopted aninnovative aerospace market approach based on Trelleborgcore values. This means that we have been able to providenot just technical solutions to our aerospace customers, butpartnerships as well. Relying on supply chain management(SCM), logistics through the Logistics Center Americas(LCA), an extensive product portfolio, multiple productionfacilities and outstanding customer service, this systemallows us to have complete airframe capability.

Innovation- integrating supply and demand

Putting into practice the process of supply chainmanagement has been an integral component to thesuccess of our approach to the market. SCM involvesdeveloping, implementing and managing supply chainoperations. The goal is to proactively meet customerrequirements as efficiently as possible. In our current

aerospace partnerships, the effectiveness of SCM meansthat our customers’ part stock is always taken care of. Lowstock is automatically replenished, and total stock iscontinuously monitored.

A service approachbased on Trelleborgcore values

Over 40,000 different seals andsealing systems are shipped fromthe various manufacturing sites toour central Logistics Centers inEurope, Asia and America. Inaddition we have completelyaligned our logistical support tomatch changing customer needs andprovide an efficient chain ofdelivery at economic cost.

Aerospace requirementsmet through Supply ChainManagement

Supply Chain Management:How does it work?

Supply Chain Management (SCM)means:

Developing

Implementing

Managing

SCM involves each aspect of thesupply chain, from raw componentsto final delivery of a finished product.The ultimate goal of SCM is to meetcustomers’ requirements as efficientlyas possible.

Our Core Values

Responsibility

Innovation

Performance

Customer focus

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Did you know?

Trelleborg Sealing Solutions is the number onesupplier of seals to the aerospace industry inEurope and number two in America.

A one-stop-shop for aerospace sealing

“Customers can come to one location to get everyseal that they need for their project,” says AntonioGarcia, aerospace segment manager, TrelleborgSealing Solutions Americas. That’s important,because our customers are looking for us to be aone-stop-shop. Our goal is to provide completeairframe capability.

“We rely on each of our locations in the Americasto do its part. By working together, we keep thesupply chain moving and are able to meet ourcustomers’ demands time and time again. Our SCMand logistics approach means that we operate likea well-oiled machine, while at the same timenurturing customer relationships.”

Responsibility- different locations, differentproducts, one goal

The LCA is located in Fort Wayne. It works diligently toensure that all parts, from O-Rings to back-up rings andmore, are available on-demand. Adherence to specificaerospace or military specifications is strictly monitored.By working to get supply contracts with group as well asnon-group suppliers, we are solidifying our productportfolio. Our locations in North America and Brazil allcontribute to the success of our aerospace partnershipapproach, from sales, to designing and engineering, toproduction and delivery.

Performance- Industry leader

Trelleborg Sealing Solutions is an industry-leading supplierto the aerospace industry, and the “not just technicalsolutions, but partnerships” approach only serves to furtherstrengthen our position in the worldwide market.Additionally, our extensive range of in-house materials,products, research and development and Finite ElementAnalysis (FEA) capabilities ensure that the ideal solutionscan be achieved for all of our customers’ applications.

Specialized manufacturing sitesworking together across theAmericas with the LCA and theMarketing Companies to deliverproducts.

Trelleborg Sealing Solutions Fort Wayne�� hydraulic seals

Trelleborg Sealing Solutions Broomfield�� Variseal®, hydraulic seals and bearings

Trelleborg Sealing Solutions Somersworth�� environmental, air delivery

Trelleborg Sealing Solutions Hudson�� airframe, environmental, engine

Trelleborg Sealing Solutions Brazil�� hydraulic seals, inventory

Trelleborg Sealing Solutions Eugene�� composite bearings, hydraulic systems

Plus numerous third-party suppliers

A business area of the Trelleborg Group

Employees: 5700

Research and Development Centers in Europe and America

30 manufacturing plants worldwide

40 Marketing Companies globally

Quality Certifications: ISO 9001:2000 and ISO/TS 16949:2002

In-house polytetrafluor-ethylene, polyurethanedevelopment and elastomer development

More than 2000 material formulations

Worldwide distribution network

Contact your local Trelleborg Sealing Solutions Marketing Company at:


Trelleborg Sealing Solutionsat a glance

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