Control units

We implement the best and most cost-effective solution for your application in our own manifold production.

 We develop every control unit according to the technical requirements and space available. This includes the technical functionality and the physical design of the manifold. We take over the development of the circuit diagram as well as the selection of the suitable valves. During the construction we focus in particular on user-friendliness, compact design, clearly arranged outlets.

 Energy efficiency and reliable operation are attained through the intelligent use of high-quality components.

We work with experienced control unit engineers and specially trained unit installation experts on 5-axis CNC centres and 4-axis CNC centres.

 Construction and production are ideally coordinated with one another in terms of materials, processing methods and tools. As the only manifold producer worldwide, we can fall back on a perfectly adapted CAM program. A continuous CAD-CAM data flow brings advantages in terms of process reliability, manifold shape and processing speed and, above all, an unbeatable lead time from the idea to the finished unit.

 At the end of the production process, we rely on individual tests on our fully automated control unit test bench in order to ensure optimal zero-defect operation and precise settings for each control unit.

Every customer receives the unit optimized for it. We leave pure contract manufacturing of units to our competitors.

All manifolds are deburred using the Thermal Energy Method. Our deburing system has the world’s largest chamber volume. We process blocks with a length of up to 580 mm.

After manual pre-deburring, the burrs are burned withing 20 millisecons in the first pass. In the second pass, the oxide layer is removed using a stoichiometric gas mixture. The assembly block is then cleaned in our state-of-the-art air-spray facility using an environmentally friendly neutral cleaner and ultrasound. The deburring process is completed with the vacuum drying.

Sophisticated switching logic, space-saving construction, reliable switching and control valve technology – hydraulic plants and systems only unfold their entire, open-topped range of services through precise control.

A defining features of Dorninger Hytronics control units is the individual arrangement of valves and connections to suit the space available. Our many years of experience with the suitability of the valves for certain applications, e.g., with regard to continuous use in three-shift operation as well as dynamics and tightness. Thereby we draw on well-known manufacturers such as Parker, Rexroth, Hydac and Sun.

Using state-of-the-art hydraulic sub plate and cartridge valves and electro-hydraulic proportional and closed loop valves allows us to meet all function, quality and flexibility requirements.

We manufacture our standard series plates for sub plate valves cost-effectively in the nominal sizes NG6 and N10. A large number of intermediate plates, adapter plates and mounting units enable a flexible, application-related combination.

Independent of the manufacturer, we implement the complete solution from the intelligent circuit diagram to the fully functionally tested control unit. We use our hydraulic competence in order to be able to provide the optimal product taking into account the technical feasibility.

In accordance with the special requirements of the plastic and rubber injection industry, we develop our switching schemes with regard to energy efficiency, dynamics and accuracy.

Already in the design process, interconnected bores are shown spatially and wall thickness checked. In order to be able to react flexibly to the installation situation, not only orthogonal holes but also spatially free holes are possible. This means that each control unit can be optimally adapted to the installation situation. In the plastic and rubber injection industry, we prefer to use proportional and control valve technology from Parker due to our positive experience.

Our test program on the test bench carries out an automated test of the unit with regard to tightness, functionality and setting values. The serial number management guarantees later access to the documented and archived test values. The tolerance specifications are continuously improved and adapted in accordance with practical experience.

We interlink the development processes with our pressing machinery customers and can therefore respond perfectly to customer wishes and requirements. The development time is shortened by using the most modern technology. Application-related solutions are developed for specific functions and needs such as reduced installation space and routing of the press units.

For the hydraulics section, it is possible to completely transfer the design responsibility to our experienced engineers, so you benefit from the specialists’ extensive mechatronics and hydraulics know-how. Our component experience with tight valves is particularly advantageous in the pressing machinery. Trust in our in-house seamlessly interlocking development tools, from the hydraulic diagram to construction and production.

The quality and freedom from defects of the press units is ensured with a hydraulic test on test benches developed in-house for this purpose with automated unit testing and documentation of all test data. All prototypes are subjected to an intensive long-term test phase. This creates tailor-made press units that optimally fulfil their purposes for a long time.

In the metallurgical industry, we offer control units that are adapted to the requirements of heavy industry. The adverse, sometimes aggressive environmental conditions require, in addition to appropriate surface protection, specially constructed designs. Integrated functions such as cooling or cylinder functions are possible the same as individually defined electrical and hydraulic interfaces.

Thanks to our experience and our flexible construction and ultra-modern manufacturing process including quality assurance, we guarantee the high reliability of our units even in heavy industry. Long-term availability of spare parts is guaranteed.

As a unit manufacturer who analyses your individual requirements and the situation on site, we can react to specific functions and special requirements in the production of control units.

Each unit is tailored to the installation space and cable routing. The hydraulic line routing can be simplified and made available with piping and connections ready for connection. We use valves regardless of the manufacturer depending on the circumstances or your personal preferences.

Custom-made solutions can e.g., include the integration of hydraulics in a unit, we have also already implemented combinations with extension boxes for the electrical control. Combination solutions with cylinders, e.g., Sun units built on cylinders are also possible along with many other special solutions.

Units with an extremely high power density are required in mobile hydraulics. The challenge for the developer is the smallest space requirement with maximum functionality.

At our company, the control unit specialists design and manufacture weight and flow-optimized versions with individually constructed designs, using the many design options with the Sun built-in valves, for example. Attention is always paid to a cost structure suitable for series production.

Design, manufacture, quality assurance and testing are standardized in-house which is why our units also score highly in the mobile hydraulics sector.