Air Over Oil Press Archives - Air-Hydraulics, Inc.

Choosing the Right Hydraulic Press for Manufacturing and Assembly

January 2, 2024January 18, 2024 Air Over Oil Press, Hydraulic

Choosing the right type of press can significantly impact productivity and quality at your factory. Let’s take a look at the details of hydraulic presses for manufacturing and assembly, as well as some potential alternatives to hydraulic presses.

Your Press Process

There are many different factory presses to choose from, and finding the right press for your needs means matching the functionality and design of the press to the needs of your process. It’s important to assess your process first, so you know what to look for in a press, and then assess the different options available, so you can find the right fit.

As you assess your process, look for the following:

Force: how much force does your process need? A few shortcuts can help you calculate force, which can help you hone in on the right-sized press.
Speed: how fast do you need your press to operate? Consider the surrounding processes and your production needs.
Job type: will your press be performing one or two jobs repetitively, or will you need to make adjustments to perform a variety of different tasks?
Dimensions: consider the dimensions of your part or workpiece, as well as the space available in your shop. This can help you determine the stroke length needed, and the possible footprint of the press.

Hydraulic Presses for Manufacturing or Assembly

The following are a few of the most common presses used in manufacturing and assembly operations. We’ve selected these press types because of their versatility, functionality, stability, and power, which makes them ideal for a variety of different manufacturing and assembly tasks.

C-Frame Hydraulic Press

The C-frame hydraulic press is a versatile choice for manufacturing and assembly. Its open-front design allows easy access to the work area for easier die changing or adjustments and also for material loading, making it suitable for a variety of tasks such as bending, stamping, and forming. Since these presses are often smaller than 2 or 4-post presses by design, they are great choices when you’re dealing with limited floor space but still need the power of full hydraulic force. These presses are typically lower in cost compared to 2 and 4-post hydraulic presses as well.

Hydropneumatic presses are also available with a C-frame design. Air-over-oil presses can provide between 2.5 and 50 tons of force, allowing these models to accomplish many of the same jobs as hydraulic presses.

2 or 4 Post Hydraulic Press

For heavy-duty applications, 2 or 4 post hydraulic presses provide stability and strength. The vertical posts on each side of the working area can either be structural, or have a guided platen that moves along the posts for perpendicularity. In either case the hydraulic cylinder or cylinders are typically mounted at the top of these posts.

With non-guided 2- or 4 – post hydraulic presses, the structural configuration simply offers more room for larger pieces of working material. Guided systems provide an even surface area of pressure, exerting force horizontally along the surface area of the guided platen, ensuring perpendicularity for tasks that require a consistent and uniform application of force. These configurations may be required for punching several dies from a sheet of metal, foam or plastic, or for other applications like metal forming and pressing over a large surface area.

Alternatives to Hydraulic Presses

The following presses are not full hydraulic presses, but they fit the bill for jobs and applications that require hydraulic power and often come with higher efficiency and lower cost and maintenance, so they are worth mentioning in the same vein. These are hydropneumatic presses, the first of which is something uniquely designed to function just like hydraulic, with a higher return on ROI.

Rapid Advance Low-Force Hydraulic Intensified Air-Over-Oil Press

A hydropneumatic press is a great alternative to a purely hydraulic press for manufacturing and assembly. The Air Hydraulics line of AH-Series Hydropneumatic Presses provide a range of 4 to 50 tons of force. Since this model combines pneumatic and hydraulic forces, it works faster than a purely hydraulic press, and also requires less maintenance and initial investment. This model’s rapid, low-force approach stroke uses a hydraulic-intensified half-inch power stroke, providing a strong finish to a steady procedure, and also provides a low-cost, energy-efficient alternative to a single or 3-phase high voltage hydraulic power unit.

Full Powerstroke Air-Over-Oil Presses

While most hydropneumatic presses deliver intensified power within a half-inch of the cylinder stroke, air-over-oil presses designed with full power strokes like our unique C-Series Air Hydraulics Presses, can be the perfect alternatives to medium force hydraulic presses.

These presses combine the advantages of hydraulic and pneumatic systems, offering a full power stroke like their hydraulic counterparts, but using compressed air for the return stroke, providing efficiency and speed. The full powerstroke air-over-oil model press provides between 2.5 and 15 tons of force, with pressure maintained throughout the entire stroke. This type of press is ideal for bushing or bearing insertion, press fit, stud insertion, and many other manufacturing and assembly tasks. These presses provide the force of a hydraulic press, with reduced maintenance demands, increased speed, quieter operation, no high-voltage power requirements and a lower upfront investment cost.

View our Air Hydraulic C-Series Presses ›

Choosing the right press for manufacturing and assembly involves a careful consideration of force, speed, and control. Hydraulic presses, along with their alternatives, offer a spectrum of options. By understanding the nuances of each type, manufacturers can make informed decisions that contribute to the efficiency and success of their operations. If you’re wondering about which press is ideal for your manufacturing or assembly needs, contact us. We can help you find the right design, force, and features for your application.

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Alternatives to Hydraulic Presses

Rapid Advance Low-Force Hydraulic Intensified Air-Over-Oil Press

Full Powerstroke Air-Over-Oil Presses

View our Air Hydraulic C-Series Presses ›

8 Benefits of Air-Over-Oil Intensifiers

December 19, 2023November 13, 2023 Air Over Oil Press

Air-over-oil intensifiers, also known as air-oil boosters, are devices designed to amplify the force generated by a pneumatic system by utilizing hydraulic principles. These intensifiers play a crucial role in applications where a higher force is required than what a standard pneumatic system can deliver. Let’s take a look at how air-over-oil intensifiers work, and what benefits they can provide.

How Air-Over-Oil Intensifiers Work

Air-over-oil intensifiers use a combination of shop air, a pneumatic cylinder, and a hydraulic cylinder to intensify the force generated. Let’s see how this process works, step-by-step.

Compressed air actuates the pneumatic cylinder, which, in turn, moves a piston.
As the piston in the pneumatic cylinder moves, it displaces hydraulic fluid (oil) from the hydraulic cylinder.
The hydraulic cylinder typically has a smaller diameter than the pneumatic cylinder. This size difference creates a force multiplication effect.
Pascal’s law dictates that the pressure in a confined fluid is transmitted equally in all directions. Therefore, the force applied to the large pneumatic piston transfers to the hydraulic piston, resulting in an increased force output.
The return stroke of the system is often accomplished using a spring or by allowing the compressed air to push the hydraulic fluid back into its reservoir.
This allows for a force output on par with that of a hydraulic system within a half-inch power stroke, but with the speed advantages of a pneumatic system. Certain models can achieve a full length power stroke, like in our C-Series Air Hydraulic Presses.

The B-Series Air-Hydraulics Booster System uses shop air to deliver between 2.5 tons to 15 tons of force. Learn more ›

Benefits of Air-Over-Oil Intensifiers

Air-over-oil intensifiers combine pneumatic speed and hydraulic force, giving them a number of functional and cost-saving benefits. Here are some key benefits of using an air-over-oil intensifier or air-oil booster.

1. Force Multiplication

The primary advantage of an air-over-oil intensifier is its ability to multiply force. By using the principles of hydraulic systems to amplify the force generated by compressed air, these intensifiers allow for higher forces than what a pure pneumatic system could achieve.

2. Increased Speed

Pneumatic systems are known for their speed and responsiveness. Air-oil boosters maintain this characteristic, providing rapid actuation and quick cycling of the system.

3. Efficiency

The intensification of force allows for more efficient use of energy. With a relatively small input of compressed air, the system can produce a significant force output, making it energy-efficient for applications that require intermittent high force. By contrast, fully hydraulic systems demand high levels of energy.

4. Cost-Effective

Compared to a full hydraulic system, air-oil boosters are more cost-effective. They offer the benefits of hydraulic force multiplication without the need for a large and complex hydraulic system.

5. Flexibility

Air-oil boosters offer flexibility in terms of force control. The operator can adjust the force output by regulating the air pressure, providing versatility for different applications and materials.

6. Compact Design

Air-over-oil intensifiers often have a more compact design compared to traditional hydraulic systems. This compact size makes it possible to fit into small spaces, while still offering a high level of power and force.

7. Intermittent Use

Air-oil boosters are well-suited for applications that involve intermittent use of high force. While continuous operation may lead to heat buildup, in scenarios with occasional heavy-duty requirements, air-over-oil intensifiers offer an effective solution.

8. Reduced Hydraulic Infrastructure

Compared to a full hydraulic system, the infrastructure requirements for an air-over-oil intensifier are typically simpler. Essentially, air-over-oil cylinders need only shop air to operate and hold no more than 1-2 gallons of oil, whereas hydraulic systems rely on reservoirs of 25 gallons or more, which can take up a decent amount of space. Hydraulic systems also require a high voltage power source, as well as a high level of maintenance. Using air-over-oil boosters instead can reduce installation and maintenance costs.

Applications for Air-Over-Oil Intensifiers

Air-oil boosters can improve speed, productivity, and functionality for a variety of different press applications. Here are a few examples of jobs that can be ideal for an air-oil booster.

1. Metal Forming and Stamping

Air-over-oil intensifiers are commonly used in metal forming and stamping processes where high force is required for a short duration.

2. Assembly Operations

Some assembly tasks demand extra force during certain stages. The intensifier provides intermittent high force that can quickly and effectively accomplish these tasks.

3. Pressing and Riveting

Applications such as pressing and riveting, where force is critical for specific stages, can benefit from the force multiplication capabilities of intensifiers.

4. Materials Testing

In materials testing scenarios where controlled force application is necessary, air-over-oil intensifiers provide a balance between precision and efficiency.

While air-over-oil intensifiers offer unique advantages, it’s essential to carefully consider the specific requirements of the application. Factors such as the level of force needed, cycle frequency, and the balance between force and speed will influence the decision to use these intensifiers in a particular manufacturing or assembly setting.

Air-over-oil intensifiers provide a hybrid solution that leverages the advantages of both pneumatic and hydraulic systems. By combining compressed air for speed and hydraulic force multiplication, these devices are valuable in applications where a balance between force and speed is essential.

How Does an Air-Over-Oil Press Work?

June 3, 2023December 8, 2023 Air Over Oil Press

An air-over-oil press uses a combination of compressed air and hydraulic fluid, to enhance the power of a pneumatically operated press, with the consistent fluid pressing action found in fully hydraulic presses. Air-over-oil press technology accomplishes the increase in power without the use of high voltage power units or incorporating noisy pumps and motors, making this an safer, more efficient and less maintenance intensive option compared to hydraulically powered press machinery.

So how does an air-over-oil press work? And what are the benefits of using an air-over-oil press? Understanding the operation and benefits can help you determine whether an air-over-oil press is right for your next application project.

How Does an Air-Over-Oil Press Work?

An air-over-oil press, also known as a hydropneumatic press, uses both pneumatic and hydraulic technology to drive the press. There are several distinct advantages of an air-over-oil press, which we’ll discuss later in the blog post. But first, how does a typical air-over-oil press actually work? Let’s go through the basic operation of a hydropneumatic press, step-by-step.

First, the operator loads the parts or material into the machine and prepares the operation.
The operator then engages the machine, which energizes a pneumatic valve.
Factory supplied air fills the cylinder, advancing the internal reservoir piston which displaces self-contained oil on the working piston, initiating a rapid advance low-force stroke.
Upon reaching the workpiece or a preset distance, a secondary power control valve is energized. This initiates the internal high pressure piston by compressing the self-contained hydraulic oil onto the working piston, producing a smooth and powerful hydraulic intensified stroke. This intensified stroke is referred to as the power stroke and is typically .500” in most systems. It can be initiated anywhere within the overall stroke of the cylinder.
When the operation is complete, both valves are de-energized and the rod returns to its original position.

The compressed air and oil work cooperatively to extend a smooth and consistent force throughout the machine press cycle. Though this description is a simplification, it outlines the general operation of the air-over-oil presses you can regularly find on the marketplace, like our AH-Series Hydropneumatic Press shown above, featuring models that deliver from 4 to 50 tons of force – a great option for the following applications:

- Riveting
- Crimping
- Punching
- Swaging
- Trimming
- Assembly

- Notching
- Joining
- Forming
- Fastening
- Marking
- Character Stamping

Air Hydraulics C-Series Air-Over-Oil Press

Then there is another, less known type of air-over-oil press, our Air-Hydraulics Press, which we refer to as our C-Series Air-Over-Oil line. These presses are uniquely designed to deliver a full length hydraulic intensified power stroke, as opposed to just a limited .500” power stroke. This is accomplished by energizing a single pneumatic or electric power valve to shift and actuate the press’ booster cylinder, compressing the self-contained hydraulics fluid directly into a separate working cylinder (ram cylinder) to intensify the entire press working stroke, just like a full hydraulic press, only powered by factory supplied air.

These presses are great for heavier applications requiring full force at over half an inch in distance, such as:

- Bushing or Bearing Insertion
- Press-Fit Assembly
- Stud Insertion

You can purchase a hydraulic intensified booster cylinder individually to power your custom press machinery.
See how it works »

Advantages of an Air-Over-Oil Press

Now that you know how two different types of air-over-oil presses work, let’s take a look at the advantages of this press technology. Air-over-oil presses offer unique advantages compared to purely pneumatic and fully hydraulic presses. Air-over-oil presses can offer increased control and efficiency compared hydraulic presses and the hydraulic technology also offers additional power compared to many purely pneumatic presses. The combination of technologies also provides a smoother operation, which can be very advantageous for processes that require higher levels of accuracy and control. Look over the following advantages of air-over-oil presses to see if they may better fit your particular operation.

Advantages of Air-Over-Oil Presses Include:

Increased Power – using self-contained hydraulic fluid power, higher force ranges can be achieved with minimal air consumption. (Up to 50+ tons with our AH-Series and up to 15 tons with the Air Hydraulics C-Series Press)
Safer – The control package for these air-over-oil press packages only require an airline connection or 120vac power to operate, unlike standard hydraulics presses which require a high-voltage power source.
Energy efficient – Without the constant power draw of hydraulic pumps and motors, air-over-oil presses require less energy to operate than standard hydraulic presses.
Quieter – Air-over-oil presses do not require the use of noisy pumps and motors, so they are much quieter than standard hydraulic presses. A small amount of exhausting air is the only noise heard during the actual cycling of the press.
Less maintenance – Air-over-oil presses require less maintenance than full hydraulic presses. Less maintenance equals less downtime, and more time for production.
Versatile – Air-over-oil presses are not limited in configuration and can be modified and designed to fit an array of application requirements
Cost-effective –In addition to being easier to maintain, air-over-oil presses also are much more affordable than full hydraulic presses, meaning a better return on your initial investment.

The right designs and configurations of an air-over-oil press can further optimize production for a specific application. If you’re looking for a powerful new press for your shop or factory, contact us. We can help you find or design a press that is powerful, cost-effective, and efficient. If you have questions about air-over-oil presses or other press designs, we’re happy to help.

Air Press vs Air Over Oil Press: What’s the Difference?

August 25, 2022March 13, 2024 Air Over Oil Press, Air Press, All

When it comes to tough assembly and metalforming jobs, a great factory press is an essential tool. But, there are many different types of presses to choose from. Two of the more affordable and easily usable types of industrial presses are air presses (AKA pneumatic presses) and air over oil presses (AKA hydropneumatic presses). So, what’s the difference between an air press vs an air over oil press?

Air Press vs Air Over Oil Press: What’s the Difference?

What is an Air Press?

An air press and an air over oil press are similar, but there are some important differences. An air press, or pneumatic press, uses compressed air in a series of cylinders to create force. The compressed gas contained in the cylinder can be regular air, mostly nitrogen and oxygen, or compressed nitrogen. When the air is compressed further in the cylinder, it creates pressure anywhere between 10psi and 5,000psi, which can then be used for a wide variety of assembly applications, riveting, punching, forming and other jobs.

What is an Air Over Oil Press?

An air over oil press, or hydropneumatic press, uses hydraulic and pneumatic technology to create force. This system uses compressed air to drive a piston that compresses hydraulic fluid. These technologies combined can create even more force than a pneumatic press, and can create force comparable to a full hydraulic press.

Air Press vs Air Over Oil Press: How Are They Similar?

Air presses and air over oil presses are similar in many ways. Both use pneumatic technology to create force. They also operate in similar ways, and have similar safety mechanisms and features. An air press and an air over oil press both require similar power needs, and have similar maintenance schedules. Compared to a purely hydraulic press, the air press and air over oil press also have less intense maintenance schedules.

Comparing an air press vs air over oil press, there are a few similarities:

Both use compressed air to generate force
Similar maintenance schedules
Similar power requirements
Similar safety mechanisms
Similar operation

Air Press Vs Air Over Oil Press: How Are They Different?

Though there are many similarities, there are also several important differences between an air press and an air over oil press. Since it uses hydraulic technology combined with compressed air, the air over oil press can exert more maximum pressure than a purely pneumatic press. An air press can exert between 150 and 5,000 lbs (2.5 tons) of force, while an air over oil press can exert between 2.5 and 50 tons of force. For this reason, an air press and an air over oil press are each ideal for different jobs and applications. An air press may be used for light applications like assembly, riveting, punching, staking, stamping, crimping, and similar tasks. An air over oil press may be used for heavier applications like bushing and bearing insertion, stud insertion, broaching, swaging, trimming, notching, and similar tasks.

Browse information and recommended presses by Industrial Press Application >

Another important difference between an air press vs an air over oil press is the costs associated with each. While they have similar maintenance schedules and costs to maintain, an air over oil press can exert more force and costs more to purchase. However, an air over oil press is generally more affordable than a purely hydraulic press. Finally, an air over oil press will be slightly larger and take up more space in your shop than an air press.

Comparing an air press vs air over oil press, there are a number of important differences:

An air over oil press can exert more maximum force than an air press
Each press is ideal for different jobs
An air over oil press costs more to purchase than an air press
An air over oil press has a larger footprint than an air press

Both an air press and an air over oil press have similarities as well as important differences. Which one is right for your shop will depend on your primary application, your budget, your shop layout, and more. If you’re unsure which type of press is right for you, contact us. We can help you find the right fit for your needs.