How an Existing 150 mm V220CC Cylinder Can Be Adapted to a 120 mm Stroke
In mold engineering, hydraulic cylinders are often selected according to the movement required by a specific application. However, situations can arise in which a Customer already has suitable cylinders in stock but the required stroke for a new project is different.
This was exactly the situation addressed by the Vega Team in a technical request concerning a V220CC hydraulic cylinder.
The Customer had several unused V220CC cylinders with a 150 mm stroke and needed to use them for a new project requiring a 120 mm stroke. The Customer therefore asked whether it was possible to purchase only a stroke reducer and install it on the existing cylinder, or whether a complete rod/piston assembly with the reducer already installed would be necessary.
The Vega Team confirmed that the solution was technically feasible, but also identified an important practical consideration: installing the reducer requires machining the cylinder rod. For this reason, Vega recommended supplying a spare rod/piston assembly with the stroke reducer already installed.
This approach could make the conversion significantly faster and easier for the Customer.
1. The Customer’s Starting Point
The Customer already had V220CC hydraulic cylinders with a 150 mm stroke that were not being used.
A new project required a shorter stroke:
Existing cylinder: 150 mm
Required stroke: 120 mm
The difference was therefore:
30 mm
Instead of purchasing completely new cylinders, the Customer wanted to know whether the existing V220CC cylinders could be adapted.
The original request specifically asked whether the stroke reducer alone could be supplied and installed by the Customer, or whether the rod/piston with the reducer installed would need to be ordered.
This is a common type of engineering question when a company wants to reuse hydraulic components already available in its inventory.
2. Why Reusing an Existing Cylinder Can Make Sense
Replacing an entire hydraulic cylinder simply because its stroke is longer than required is not always the most efficient solution.
If the existing cylinder is otherwise suitable for the application, adapting its effective stroke can potentially allow the Customer to reuse an existing component.
This can offer several practical benefits:
- reduced component purchasing;
- better use of existing inventory;
- shorter procurement times;
- reduced waste;
- simplified spare-parts management;
- faster implementation of a new mold project.
However, the possibility of modifying a cylinder must always be evaluated from a technical standpoint.
The key question is not simply:
“Can the stroke be reduced?”
It is:
“What is the correct and reliable way to reduce it?”
3. The V220CC as the Basis for the Solution
The V220CC is a compact, long-stroke hydraulic cylinder designed by Vega for linear movements in injection molds.
According to Vega’s official documentation, the V220CC range includes standard piston bores from 32 to 100 mm and strokes from 20 to 350 mm. Vega also states that the cylinders can be customized according to Customer requirements through a special project.
The official V220CC product pages currently list configurations including Ø40 mm and Ø50 mm bores and several standard strokes, including 150 mm.
This makes the V220CC a useful platform for applications where the required movement does not necessarily correspond to a completely standard cylinder configuration.
4. The Technical Question: Can the Stroke Reducer Be Installed Separately?
The Customer’s question was very specific.
Would it be possible to purchase:
stroke reducer only
and install it on the existing V220CC?
Or would Vega need to supply:
rod/piston + stroke reducer already installed?
The Vega Team’s answer clarified the technical procedure.
The reducer requires a modification to the rod: the rod must be drilled and internally threaded, after which the fixing screw is secured using Loctite.
Therefore, the reducer is not simply an accessory that can be attached to the existing cylinder without preparation.
5. Machining the Rod
The installation procedure described by the Vega Team involves two fundamental machining operations:
Drilling
A hole must be made in the rod.
Internal threading
The hole must then be internally threaded to accommodate the fixing screw.
Once the mechanical preparation has been completed, the screw is fixed using Loctite.
For a cylinder manufacturer with the appropriate machinery and experience, this is a relatively straightforward operation.
But that does not necessarily mean that it is equally convenient for the end Customer.
6. A Simple Operation for Vega May Not Be the Best Solution for the Customer
This was one of the most interesting aspects of the technical response.
The Vega Team explained that the machining operation was not complicated for Vega, but questioned whether it would be equally simple for the Customer.
This distinction is extremely important in industrial engineering.
A technically possible modification is not automatically the best maintenance solution.
The Customer may not have:
- suitable machining equipment;
- the appropriate tooling;
- the required fixtures;
- the necessary dimensional controls;
- experience machining hydraulic-cylinder rods.
Consequently, the technically simplest solution for the manufacturer can be different from the most practical solution for the end user.
7. Vega’s Alternative: A Complete Spare Rod/Piston
Rather than recommending that the Customer machine the existing rod, the Vega Team proposed a different approach.
The recommendation was to purchase a:
spare rod/piston assembly with the stroke reducer already installed.
This changes the maintenance operation considerably.
Instead of machining the existing cylinder, the Customer can replace the relevant assembly with a component that has already been prepared by Vega.
8. Why a Pre-Assembled Solution Is More Practical
The Vega Team explicitly highlighted the main advantage:
the replacement would be very fast and easy.
This is particularly valuable in mold manufacturing and maintenance, where downtime can be costly.
The Customer does not need to organize machining operations before using the cylinder.
The conversion becomes essentially a component-replacement operation rather than a machining project.
9. From 150 mm to 120 mm
The technical requirement can be summarized simply:
Existing V220CC
↓
150 mm stroke
↓
New application
↓
120 mm required stroke
↓
Stroke reduction required
↓
30 mm difference
The proposed solution was to install a stroke reducer on the rod/piston assembly.
Instead of supplying the reducer as a completely independent component, Vega proposed supplying the rod/piston assembly with the reducer already installed.
10. Why the 30 mm Difference Matters
The required reduction was:
150 mm − 120 mm = 30 mm
This means that the original cylinder had more available stroke than the new application required.
The purpose of the reducer was therefore not to change the hydraulic characteristics of the cylinder itself, but to limit the effective movement to the required value.
This distinction is important.
The hydraulic cylinder remains the same basic actuator, while the mechanical configuration limits the usable stroke.
11. Stroke Reduction Versus Cylinder Replacement
When an existing cylinder has excessive stroke, there are generally two possible approaches.
Option 1 — Replace the cylinder
The Customer purchases a new cylinder with the required 120 mm stroke.
Option 2 — Adapt the existing cylinder
The Customer retains the existing 150 mm V220CC and introduces a suitable stroke-reduction solution.
The second option can be particularly attractive when the cylinders are already available in stock.
In this case, the Customer specifically wanted to determine whether the existing cylinders could be reused.
12. The Importance of the Rod/Piston Assembly
The proposed spare part is not simply a generic mechanical spacer.
The Vega Team recommended a rod/piston assembly with the reducer installed.
This is significant because the rod is a functional component of the hydraulic cylinder.
The modification must therefore be performed in a controlled manner so that the resulting assembly is suitable for the cylinder and application.
Supplying the prepared component shifts the machining operation from the Customer’s workshop to the cylinder manufacturer.
13. Why Manufacturer Preparation Can Reduce Risk
Having the modification performed by the cylinder manufacturer offers an important practical advantage.
The manufacturer already understands:
- the cylinder geometry;
- the rod construction;
- the appropriate machining procedure;
- the correct fixing method;
- the relationship between the reducer and the cylinder assembly.
In this case, the Vega Team already knew the required modification and could supply the prepared rod/piston assembly.
14. The Role of Loctite
The documented installation procedure specifies the use of Loctite to secure the fixing screw after the rod has been drilled and internally threaded.
This is a small but important detail.
The reducer is not simply positioned mechanically; its fixing method is part of the overall solution.
When a component is subjected to repeated hydraulic movements and mechanical loads, the integrity of the fixing arrangement is essential.
15. A Better Way to Think About Cylinder Modification
This Customer case demonstrates a useful principle:
When modifying a hydraulic cylinder, the best solution is not necessarily the one involving the fewest purchased parts.
A reducer alone may appear to be the simplest purchase.
But if the Customer must then:
- disassemble the cylinder;
- machine the rod;
- drill it;
- thread it;
- install the screw;
- apply the fixing compound;
- reassemble the cylinder;
the overall process becomes considerably more involved.
A prepared rod/piston assembly may therefore provide greater practical value.
16. Reducing Maintenance Time
The Vega Team specifically emphasized the speed and simplicity of replacing the prepared assembly.
For a mold builder or maintenance department, this can be particularly important.
A shorter intervention means less time spent on:
- machine preparation;
- component machining;
- testing;
- reassembly;
- troubleshooting.
The value of a spare part should therefore be evaluated not only by its purchase price but also by the time required to install it.
17. The Value of Existing Inventory
The original Customer situation also highlights an important inventory-management issue.
The Customer already had unused V220CC cylinders with a 150 mm stroke.
If those cylinders can be adapted to the new application, existing inventory can be converted into useful production equipment.
This can be particularly advantageous for companies that maintain stocks of hydraulic cylinders for different mold projects.
Instead of having to purchase a new cylinder every time a different stroke is required, the company can investigate whether an existing cylinder can be technically adapted.
18. The V220CC Is Designed for Mold Applications
Vega’s official documentation identifies the V220CC as a long-stroke compact hydraulic cylinder for mold applications.
The V220CC is particularly associated with linear movements such as carts, pins and plugs that can create undercuts in plastic injection molds. Vega also identifies the V220CC under Ejection Plate Movement in its hydraulic-cylinder catalog.
This makes the platform particularly relevant to applications where precise hydraulic movement is required within limited mold space.
19. Compact Design and Customization
The V220CC combines a compact design with long-stroke capability.
Vega states that the cylinder body is manufactured from 7075 aluminum alloy and closed by steel flanges. The range is also designed for customization according to Customer requirements.
This customization capability is relevant to the Customer case because the requirement was not simply for a standard cylinder.
The requirement involved adapting an existing configuration to a different effective stroke.
20. Sensors and Stroke Monitoring
V220CC cylinders can also be configured with magnetic stroke sensors.
Vega’s official product pages state that the V220CC can be supplied with preparation for magnetic switches and identify the MSU4 magnetic switch as an accessory for the model.
Stroke monitoring can be particularly useful when the cylinder is integrated into an automated injection-molding machine.
However, the Customer documentation for this specific case does not state that a sensor was part of the requested modification. Therefore, it should be considered a general V220CC capability rather than a documented element of this particular application.
21. A Practical Retrofit Strategy
The Customer case can be viewed as a small retrofit project.
Existing condition
V220CC cylinder with:
150 mm stroke
New requirement
Application requiring:
120 mm stroke
Proposed technical approach
Install a:
stroke reducer
Manufacturing requirement
Machine the rod with:
drilling + internal threading
Fixing
Screw + Loctite
Vega’s recommended implementation
Pre-assembled spare rod/piston with stroke reducer
Expected practical benefit
Fast and easy replacement.
22. Why This Is More Than a Simple Spare-Part Request
At first glance, the Customer’s request appears to be a question about purchasing an accessory.
In reality, it involves several engineering considerations:
- existing cylinder compatibility;
- required stroke;
- mechanical modification;
- rod machining;
- fixing method;
- installation capability;
- downtime;
- spare-part strategy.
The Vega Team’s response addressed these points by moving beyond the question of whether the reducer could be supplied separately and proposing a more practical implementation.
23. The Manufacturer as a Technical Partner
The case illustrates the value of technical support from the cylinder manufacturer.
The Customer did not simply receive a product number.
Instead, Vega evaluated the proposed modification and considered how easily the Customer could actually implement it.
The resulting recommendation was:
do not necessarily machine the existing component at the Customer’s facility; instead, supply the modified rod/piston assembly.
This is an example of application-oriented technical support.
24. What Should Be Checked Before Applying a Stroke Reducer?
Although the documented case confirms the feasibility of the proposed solution, a stroke-reduction modification should always be evaluated for the specific cylinder and application.
Important parameters include:
- cylinder model;
- bore;
- original stroke;
- required stroke;
- rod geometry;
- available space;
- mechanical loads;
- operating pressure;
- mounting configuration;
- required position control.
The official V220CC documentation states that the cylinders are designed for mineral-based hydraulic fluids and provides the relevant operating specifications for the product family.
25. A General Engineering Lesson
The Customer case provides a useful lesson for mold designers and maintenance engineers.
When an existing hydraulic cylinder has a stroke that is longer than required, there is no need to assume immediately that the entire cylinder must be replaced.
The correct process is:
1. Identify the existing cylinder
2. Define the required stroke
3. Calculate the difference
4. Verify whether a stroke-reduction solution is available
5. Determine the required machining
6. Decide whether the modification should be performed by the manufacturer
7. Select the most practical replacement strategy
In this case, the Vega Team recommended the pre-assembled rod/piston solution because it would make replacement much faster and easier.
26. Conclusion
This Customer case shows how an existing hydraulic cylinder can potentially be adapted to a new mold requirement without replacing the complete cylinder.
The Customer had unused V220CC cylinders with a 150 mm stroke but needed a 120 mm stroke for a new project.
The initial question was whether the Customer could simply purchase a stroke reducer and install it independently.
The Vega Team explained that installation requires drilling and internally threading the rod, followed by fixing the screw with Loctite.
Although the operation was straightforward for Vega, the Team recognized that it might not be equally convenient for the Customer.
The recommended solution was therefore to supply a spare rod/piston assembly with the stroke reducer already installed. According to the Vega Team, this would make the replacement very fast and easy.
The broader lesson is valuable for injection-mold manufacturers:
When an existing hydraulic cylinder is suitable except for its stroke, a properly engineered stroke-reduction solution can be an efficient alternative to replacing the complete cylinder.
And when the required modification involves machining a critical component such as the cylinder rod, having the manufacturer supply a prepared replacement assembly can simplify the intervention and reduce the work required at the Customer’s facility.
Useful and Verified URLs
1. V220CC Long-Stroke Compact Hydraulic Cylinders
The official Vega page describes the V220CC family, including its long-stroke design, standard bore and stroke ranges, customization possibilities and operating characteristics.
V220CC Long-Stroke Compact Hydraulic Cylinders – Vega Cylinders
2. V220CC Hydraulic Cylinder – Product Configuration
This official product page provides the V220CC configuration options, including Ø40 mm and Ø50 mm bores and 150 mm stroke options. It also provides information about versions prepared for magnetic switches.
V220CC Hydraulic Cylinder – Vega Cylinders
3. Hydraulic Cylinders for Injection Molds
This is the main official catalog page for Vega hydraulic cylinders for plastic injection and die-casting molds. It identifies the V220CC among the cylinders used for ejection-plate movement.
Hydraulic Cylinders for Injection Molds – Vega Cylinders
4. Ejection Plate Movement
This official Vega category specifically lists the V220CC as a long-stroke compact hydraulic cylinder for ejection-plate movement in injection molds.
Hydraulic Cylinders for Ejection Plate Movement – Vega Cylinders
5. Vega Hydraulic Cylinder Catalog
The official catalog provides access to the different Vega hydraulic-cylinder families and their 3D drawings and configurations.
