A Customer Case: Ø50 mm Bore, Two 50 mm Strokes and Compatibility With an Existing Cylinder
In injection molds, some applications require movements that cannot be handled efficiently by a standard single-stroke hydraulic cylinder.
A typical example is a mechanism requiring two distinct linear movements, where the cylinder must provide two separate stroke stages rather than simply one continuous stroke.
A Customer contacted Vega with a specific requirement: a double-stroke hydraulic cylinder with a Ø50 mm bore and two 50 mm strokes, while maintaining the same flange and end-stroke-switch characteristics as a cylinder previously purchased.
The Vega Team confirmed that a Ø50 mm double-stroke cylinder was technically feasible. Before preparing the quotation, however, the Vega Team asked the Customer to confirm whether the required configuration was actually 50 + 50 mm, or whether a different combination of strokes was needed. At the same time, Vega suggested evaluating whether the bore could be reduced from Ø50 mm to Ø40 mm, as used on previous cylinders.
This relatively simple exchange illustrates an important engineering principle:
A special hydraulic cylinder should be designed around the actual movement required by the mold, rather than simply reproducing the dimensions of an existing cylinder.
1. The Customer’s Requirement
The Customer requested a quotation and 3D model for a:
- double-stroke hydraulic cylinder;
- Ø50 mm bore;
- two 50 mm strokes;
- flange;
- end-stroke switches;
- configuration similar to a previously purchased cylinder.
The requested movement was therefore:
50 mm + 50 mm
rather than simply a conventional:
100 mm single stroke.
This distinction is important when designing a special cylinder.
2. Why a Double-Stroke Cylinder Can Be Useful
A double-stroke cylinder can be used when a mold mechanism requires two different stages of movement.
Instead of treating the movement as one continuous 100 mm stroke, the cylinder can be designed around two separate movements.
Conceptually:
Initial position
↓
First stroke
↓
Intermediate position
↓
Second stroke
↓
Final position
The available Customer documentation does not specify the exact mold mechanism being moved, so it would be incorrect to assign a particular application to this case.
What is documented is that the Customer specifically required two 50 mm strokes.
3. 50 + 50 mm Is Not Automatically the Same as 100 mm
This is one of the most important points when discussing a double-stroke cylinder.
A standard cylinder with:
100 mm stroke
is not necessarily equivalent to a cylinder designed for:
50 + 50 mm.
The two configurations may have different requirements concerning:
- intermediate position;
- stroke sequence;
- mechanical stops;
- end-stroke detection;
- overall geometry;
- mounting;
- control logic.
For this reason, the Vega Team specifically asked the Customer to confirm whether the required configuration was 50 + 50 mm or different.
4. Vega Confirmed the Feasibility of the Ø50 mm Version
The first technical conclusion was positive.
The Vega Team confirmed the feasibility of a double-stroke cylinder with a Ø50 mm bore.
This meant that the application could proceed to the next stage of engineering.
However, feasibility of the basic concept does not automatically mean that every requested dimension has already been finalized.
The stroke configuration still needed to be confirmed.
5. Why the Stroke Configuration Had to Be Confirmed
Before preparing the quotation, Vega needed to know exactly how the cylinder should be configured.
The Customer had indicated:
50 + 50 mm
but the Vega Team explicitly asked whether this was the definitive configuration or whether a different combination was required.
This is a good example of why special-cylinder projects should be technically defined before commercial quotation.
A change in stroke configuration can affect:
- cylinder dimensions;
- rod geometry;
- internal components;
- overall length;
- end positions;
- sensors;
- mold installation.
6. The Alternative: Reducing the Bore From Ø50 to Ø40 mm
The Vega Team also proposed another important design question:
Could the bore be reduced from Ø50 mm to Ø40 mm?
The reason was that the Customer had previously used cylinders with the smaller bore.
This is a typical example of technical optimization.
If Ø40 mm provides sufficient force for the application, there may be no reason to use a larger Ø50 mm cylinder.
The final choice should therefore be based on the actual force requirement of the mold.
7. Why Bore Diameter Matters
Hydraulic cylinder force is directly related to piston area.
The basic equation is:
F = P × A
For a circular piston:
A = π × D² / 4
Therefore, increasing the bore diameter increases the available hydraulic force.
For example:
Ø50 mm piston
Area ≈ 1,963 mm²
Ø40 mm piston
Area ≈ 1,257 mm²
The Ø50 mm piston has approximately 56% more piston area than the Ø40 mm version.
Therefore, at the same hydraulic pressure, the Ø50 mm cylinder can theoretically generate significantly more force.
But that additional force is useful only if the application actually requires it.
8. Why the Smaller Cylinder May Be Preferable
If the mold mechanism does not require the additional force of the Ø50 mm cylinder, using Ø40 mm can provide several potential advantages:
- reduced overall dimensions;
- lower oil volume;
- lower flow requirement for a given speed;
- potentially lower weight;
- easier installation.
The Vega Team therefore did not simply assume that the largest requested bore was necessary.
Instead, it asked whether the Customer could use the Ø40 mm configuration already used in previous applications.
9. Cylinder Force and Hydraulic Flow
Bore selection affects not only force but also the hydraulic flow required to achieve a given speed.
The relationship is:
Q = A × v
where:
- Q = hydraulic flow;
- A = piston area;
- v = piston speed.
A larger piston requires more hydraulic flow for the same linear velocity.
Therefore, cylinder sizing should consider at least:
force + speed + flow + available space.
Selecting a cylinder simply because it has a larger bore is not necessarily the best engineering solution.
10. The Importance of the Existing Cylinder
The Customer specifically requested that the new cylinder have characteristics such as the flange and end-stroke switches of a previously purchased cylinder.
This is an important consideration in mold engineering.
When an existing cylinder configuration has already been integrated into a mold, reproducing its mechanical interface can simplify the design of a new application.
It can reduce the need to modify:
- mold plates;
- mounting holes;
- mechanical interfaces;
- sensor installation;
- hydraulic connections.
11. Compatibility Can Be More Important Than Standardization
A standard cylinder is not necessarily the best choice if it requires extensive modification to the mold.
Conversely, a customized cylinder may be more efficient if it allows the Customer to maintain an existing interface.
The Customer’s request for the same flange and end-stroke characteristics illustrates this approach.
The objective is not simply to buy a standard product.
The objective is to achieve the required movement while integrating the cylinder efficiently into the mold.
12. End-Stroke Detection
The Customer also requested end-stroke switches.
Position detection can be particularly important in a double-stroke system because the control system may need to distinguish between different positions during the sequence.
Depending on the final cylinder configuration, position detection can be used to determine whether the piston has reached a defined position and to communicate that information to the machine control system.
The current Vega V220CC product range supports magnetic-switch configurations, including MSU4 sensors.
13. The V220CC Platform and Customization
The V220CC is one of Vega’s compact long-stroke hydraulic-cylinder families.
The official Vega documentation describes the V220CC as a compact cylinder for linear movement, with 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.
This makes the V220CC platform relevant when a mold requires a configuration that does not correspond exactly to a standard catalog combination.
14. A Double-Stroke Cylinder Requires Application-Based Design
The important point is that the double-stroke configuration should be designed according to the mold’s actual sequence.
The engineering process should therefore begin with:
What must the mold mechanism do?
and not simply:
Which cylinder is available?
The required movement can then be translated into:
- first stroke;
- second stroke;
- force;
- speed;
- bore;
- mounting;
- position detection.
15. The Engineering Sequence for a Special Cylinder
A useful design workflow is:
Step 1 — Define the mold movement
Determine exactly what the hydraulic cylinder must move.
Step 2 — Define the positions
Identify:
- starting position;
- intermediate position;
- final position.
Step 3 — Define the strokes
For example:
50 + 50 mm
Step 4 — Calculate the required force
Determine the actual mechanical load.
Step 5 — Select the bore
Compare possible configurations such as:
Ø40 mm vs Ø50 mm
Step 6 — Define the mounting interface
Verify the flange and fixing arrangement.
Step 7 — Define position detection
Determine which end-stroke sensors are required.
Step 8 — Verify the complete installation
Check the cylinder against the available space and mold geometry.
Step 9 — Finalize the special configuration
Only after these points have been confirmed should the final quotation and model be prepared.
16. Why Vega Asked Questions Before Quoting
The Customer had asked for an offer and model, but the Vega Team did not immediately finalize the configuration.
Instead, it confirmed basic feasibility and requested clarification on:
- whether the strokes were 50 + 50 mm;
- whether the bore could be reduced from Ø50 to Ø40 mm.
This is good engineering practice.
A quotation based on incomplete technical information can lead to a component that is technically correct according to the written specification but unsuitable for the actual mold.
17. The Value of Previous Applications
The reference to the Customer’s previous cylinders was particularly useful.
The Vega Team knew that Ø40 mm cylinders had been used previously and therefore proposed evaluating that bore again.
Previous applications can provide valuable information about:
- required force;
- installation space;
- successful bore sizes;
- fixing dimensions;
- sensor arrangements;
- operating conditions.
Reusing validated design principles can reduce unnecessary engineering work.
18. Customization Does Not Mean Starting From Zero
A special hydraulic cylinder does not necessarily require a completely new product architecture.
It can be based on an existing platform while modifying selected parameters.
For example:
standard platform
special stroke configuration
specific flange
specific sensors
=
application-specific hydraulic cylinder
Vega explicitly states that V220CC cylinders can be customized through a special project.
19. Why a 50 + 50 mm Configuration Needs Careful Definition
A double-stroke system introduces an intermediate position.
That means the design must establish:
Position 0 → 50 mm → 100 mm
if the intended sequence is two consecutive 50 mm movements.
But the mechanical system may require something different.
For example, the second movement could involve a different mechanical function or a different reference position.
The Customer documentation does not provide enough information to define the actual mold sequence, which is why the Vega Team appropriately asked for confirmation before proceeding.
20. The Customer Case in Numbers
| Parameter | Requirement |
|---|---|
| Cylinder type | Double-stroke hydraulic cylinder |
| Requested bore | Ø50 mm |
| First stroke | 50 mm |
| Second stroke | 50 mm |
| Total movement if consecutive | 100 mm |
| Flange | Required |
| End-stroke switches | Required |
| Alternative bore considered | Ø40 mm |
| Basis for Ø40 mm proposal | Previous cylinders used by Customer |
The documented request and Vega’s technical response confirm these parameters.
21. The Main Engineering Lesson
The most important lesson from this Customer case is:
A double-stroke hydraulic cylinder should be designed around the actual sequence and force requirements of the mold, not simply around the total distance that the mechanism must travel.
The Customer requested two 50 mm strokes.
The Vega Team confirmed that a Ø50 mm double-stroke cylinder was feasible, but requested clarification of the exact stroke combination before proceeding with the offer.
At the same time, Vega questioned whether the Ø50 mm bore was really necessary and suggested considering Ø40 mm based on the Customer’s previous applications.
This is a good example of engineering optimization:
define the movement → calculate the force → select the bore → define the interface → define the sensors → finalize the cylinder.
22. Conclusion
This Customer case demonstrates how a special hydraulic-cylinder requirement for an injection mold can be transformed into a structured engineering project.
The Customer requested a double-stroke hydraulic cylinder with a Ø50 mm bore and two 50 mm strokes, together with a flange and end-stroke switches matching the characteristics of a previously purchased cylinder.
The Vega Team confirmed the feasibility of the Ø50 mm double-stroke concept, but requested confirmation of the exact stroke configuration and whether the bore could be reduced to Ø40 mm.
The possibility of using a smaller bore is an important example of application-based optimization. If the mold mechanism does not require the additional force of a Ø50 mm piston, a Ø40 mm solution may reduce dimensions and hydraulic requirements.
At the same time, maintaining the flange and end-stroke characteristics of an existing cylinder can simplify integration into a new mold.
The broader lesson is clear:
The best hydraulic cylinder is not necessarily the largest or the most powerful one. It is the cylinder whose stroke, force, mounting configuration and position control are correctly matched to the actual function required by the mold.
For special applications, the most effective approach is therefore:
mold movement → stroke sequence → force → bore → mounting → sensors → customized cylinder.
Useful and Verified URLs
1. V220CC Long-Stroke Compact Hydraulic Cylinders
The official Vega product page describes the V220CC as a compact long-stroke hydraulic cylinder, gives the standard bore and stroke ranges, and confirms that the cylinder can be customized according to Customer requirements.
V220CC Long-Stroke Compact Hydraulic Cylinders – Vega Cylinders
2. V220CC Product Configurator
This is the official Vega product page for the V220CC. It allows selection of bore, stroke, rod-end type and cylinder version, and also identifies versions prepared for magnetic switches.
V220CC Hydraulic Cylinder – Vega Cylinders
3. Hydraulic Cylinders for Molds
The official Vega catalog page groups the hydraulic cylinders according to application and identifies the V220CC under Ejection Plate Movement. It also states that standard fixing combinations can be customized according to Customer requirements.
Hydraulic Cylinders for Molds – Vega Cylinders
4. Ejection Plate Movement
This official Vega category specifically lists the V220CC among the hydraulic cylinders designed for moving ejection plates in plastic injection molds.
Ejection Plate Movement Hydraulic Cylinders – Vega Cylinders
5. Vega Hydraulic Cylinder Shop
The official Vega shop provides access to the hydraulic-cylinder range, 3D configurator and available accessories, including V220CC magnetic switches.
