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Home Electro hydraulic drive solutions Customized solutions HKAL EMG hydraulic cylinder
EMG ESZ Electro-Servo Cylinder
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Installation and Operating Instructions

HKAL EMG hydraulic cylinder

HKAL EMG Hydraulic Cylinder – Compact Power for Demanding Environments

The HKAL EMG hydraulic cylinder is a versatile and robust electro hydraulic actuator designed for precise linear motion in rigorous industrial applications. Featuring EMG’s unique “motor under oil” technology, this actuator combines high durability, adaptability, and efficient performance, making it a reliable solution where conventional mechanical or pneumatic systems may fall short.

Advanced Design and Reliable Operation

Engineered for straightforward integration and long-term functionality, the HKAL EMG hydraulic cylinder offers:

  • Hermetically sealed internal motor: Complete protection for the motor and windings against dirt, dust, moisture, and harsh ambient conditions.
  • Direct flange connection system: Eliminates the need for external pipes or hoses, reducing leak risks and simplifying installation and maintenance.
  • Consistent mechanical output: Mechanical force is generated directly by a gear pump and remains independent of piston stroke or position.
  • Adjustable force and speed: Integrated pressure control valve and a variety of pump flow rates to suit your application’s dynamic requirements.
  • Hydraulic locking: Dual lowering brake valves securely maintain stroke position even when power is disconnected.
  • Protection from shocks and load peaks: Specialized valve technology guards against sudden stress and operational impacts.

Key Features and Customer Benefits

  • Ultra-compact, durable design: IP66 protection, resistant to vibration and shock.
  • Simple integration: Quick installation and straightforward connection to plant control systems, minimizing commissioning time.
  • Reduced maintenance: Fewer external components mean longer life and less frequent service intervals.
  • Smart actuator technology: Enhanced efficiency in operation and control.
  • Customizable configurations: Options for corrosion protection, ATEX explosion protection, and temperature ranges from -40 °C to +70 °C.
  • Optional sensors: Inductive proximity switches, magnetostrictive displacement transducers, and more for integrated monitoring.
  • Manual override: Hand pump available for manual actuation if power fails.
  • Industrial-grade connectors: Flexible power connections up to 500 V/20 A for reliable operation in tough settings.

Applications

The HKAL EMG hydraulic cylinder is ideal for:

  • Mining and conveyor technology
  • Mechanical engineering and plant construction
  • Power generation
  • Valve engineering and hydraulic steel constructions
  • Renewable energy systems, including solar and water power

Tested in global reference projects—from guiding conveyor rollers to operating railcar dumpers and actuating baffle walls—the HKAL provides robust and dependable performance under the most demanding industrial conditions.

Share:
  • Design and functionality
  • Innovation and customer benefits
  • Delivery standard and special designs
  • Technology & applications
  • Reference projects
  • Data sheet
Design and functionality

Design and functionality

Wherever a defined, straight movement is required in or on a plant, machine or piece of apparatus, the Hydraulic Compact Actuator Linear is a natural choice. This is particularly true when a dependable actuator is needed which would be too difficult or expensive to realize using mechanical or pneumatic systems.

Based on EMG‘s specific „motor under oil design“, EMG has created a rugged actuator, suitable for applications with the toughest environmental conditions. Compared to conventional hydraulic systems, the built-in motor and the motor winding are protected from any harmful environmental impacts using hermetic casing.

– A gear pump (driven by a 2 pole rotary current asynchronous motor) generates hydraulic pressure, which is led through suitable valves and channels directly to the upper or lower side of the hydraulic cylinder piston.

– Thanks to a special flange accommodation on the cylinder, there is no need for pipe and hose connections to ensure the oil flow.

– The mechanical power available on the piston rod depends on the generated hydraulic pressure and the piston surface. The actual power is independent of the piston position or the cylinder stroke.

– A pressure control valve allows for a variable adjusting force within certain limits.

– Two lowering brake valves make sure that the actual stroke position is hydraulically locked and maintained once the system has been separated from the motor power supply.

– A broad selection of pumps with various flow rates ensures that a range of movement speeds is available for the various sizes.

– Specific valve technology helps protect the actuator from sudden load peaks resulting from blows and shocks occurring during operation.

Innovation and customer benefits

Innovation and customer benefits

– SMART ACTUATOR CONCEPT

– COMPACT DESIGN

– IDEAL WEIGHT / PERFORMANCE RATIO

– INSENSITIVE TO DIRT

– PROTECTION FROM LOAD PEAKS

– NO PIPE / HOSE CONNECTIONS

– HIGH QUALITY STANDARD

– GREEN ACTUATOR TECHNOLOGY

– REDUCED COMMISSIONING TIME

– SIMPLE INTEGRATION IN MACHINE CONTROL SYSTEM

– REDUCED SERVICE DEMAND

– LONG SERVICE LIFE AND MAXIMUM AVAILABILITY

– LOW PROJECT COSTS

Delivery standard and special designs

Delivery standard and special designs

The application and ambient conditions specified by the customer and the user determine the selection and modification of the Hydraulic Compact Actuator Linear HKAL (performance, frequency of operation, control functions) and its technical design (corrosion protection, explosion protection, protection against bursts of pulses and vibration).

Special designs to Built-in motor

  • Insulation class H
  • Thermal winding protection (PTC) with thermistors
  • Heating of motor winding (and hydraulic fluid)

Special designs to Sensors / control

  • Inductive proximity switches M12 x 1 at any intermediate location
  • Magnetostrictive displacement transducer across the cylinder stroke
  • Sensor voltage: 20…28 V DC (other voltages upon request)
  • Signal type: analogue (4…20 mA)
  • Temperature range: -20 °C… +80 °C
  • Variable speed drive using a proportional valve in combination with a displacement transducer and a suitable PLC
  • Hand pump for manual activation of the actuator in case of a failure

(e.g. voltage breakdown)

Special designs to Accommodations and fasteners for cylinders

– Tangential feet; bearing block; cardan bearing

Special designs to Climate / temperature range

– Cold design (F) for ambient temperatures of -40 °C…+40 °C (standstill heating for motor winding recommended), hydraulic cylinder with specific ice wiper

– High temperature design (W) for ambient temperatures of -10 °C …+70 °C; hydraulic cylinder with PTFE and VITON seals

Special designs to Plug-in connection

Equipment of the electrical connection box with an industrial connection to IEC/EN 60309-1

Mechanical features:

  • Very compact design; protection IP 66; bayonet locking
  • Spring-loaded contacts for constant contact pressure and lower contact resistance
  • Connectors with fastening protection even in case of shocks and vibration

Electrical features:

  • Voltage: max. 500 V, current: max. 20 A
  • Equipment: max. 6 PH + E
  • Silver butt contact system with metal braid for ideal current transmission
  • Contact protection of live parts (IP 2X with open cover)

Special designs to Explosion protection

  • Explosion-proof design with EC type examination certificate as per Directive 94/9 EC (ATEX), ignition protection design „Increased safety Ex e“ in accordance with standards EN 60079-0, EN 60079-3, EN 13463-1, EN 13463-5 and EN 13463-8
  • Ex marking: II 2G ck Ex e II T4 -20 °C ≤ Ta ≤ +50 °C
  • EC type examination certificate: BVS 06 ATEX E 039 X
  • Item designation: equipment group II / category 2 G
  • Application: gas explosion protection in open-pit mining, zones 1 and 2

Please note: HKAL for use in atmospheres with dust explosion hazard (zones 21 and 22) upon request.

Technology & applications

Technology & applications

  • HKA –  robust actuator for Mining industry
  • STEERING FLAP – Guidance of the material flow via flap operation
  • CONVEYOR BELTS – Conveyor belts with different functions and different operation of the material flow.
  • Deflector or Bulging flap
  • Conveyor alignment
Reference projects

Reference projects

HKAL in conveyor guide roller station

AFB 60 excavated material conveyor bridge, open-pit mine Reichwalde, Germany

Customer: VATTENFALL Mining AG

HKAL as wheel lock

Railcar dumping system at Ventspils harbour, Latvia

Customer: FAM Magdeburger Förderanlagen und Baumaschinen GmbH

HKAL on a conveyor chute

Coal stockyard, Boxberg power plant, Germany

Customer: VATTENFALL Generation AG

HKAL as clamping element for bucket chain

Ship unloader, Walsum power plant, Germany

Customer: FAM Magdeburger Förderanlagen und Baumaschinen GmbH

HKAL as baffle wall actuator

AFB 60 excavated material conveyor bridge, open-pit mine Reichwalde, Germany

Customer: VATTENFALL Mining AG

HKAL for chute regulation

AFB 60 excavated material conveyor bridge, open-pit mine Reichwalde, Germany

Customer: TAKRAF GmbH

Data sheet

Data sheet

DATA SHEET

emg-hkal-references

EMG_ELDRO-HKAL_EN

Related products

EMG ELDRO® – New Generation

EMG ESSE

Electro hydraulic actuators EMG

EMG ESZ Electro-Servo Cylinder

Intelligent automation technology for wastewater treatment plant

EMG Electro hydraulic actuators

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