{"id":2773,"date":"2024-03-07T15:41:28","date_gmt":"2024-03-07T14:41:28","guid":{"rendered":"https:\/\/www.bf-hydraulik.com\/encyclopedia\/plunger-cylinder\/"},"modified":"2026-04-15T11:52:43","modified_gmt":"2026-04-15T09:52:43","slug":"plunger-cylinder","status":"publish","type":"encyclopedia","link":"https:\/\/www.bf-hydraulik.com\/en\/plunger-cylinder\/","title":{"rendered":"Plunger cylinder"},"content":{"rendered":"\t\t<div data-elementor-type=\"wp-post\" data-elementor-id=\"2773\" class=\"elementor elementor-2773 elementor-966\">\n\t\t\t\t\t\t<section class=\"elementor-section elementor-top-section elementor-element elementor-element-735b55f8 elementor-section-boxed elementor-section-height-default elementor-section-height-default\" data-id=\"735b55f8\" data-element_type=\"section\">\n\t\t\t\t\t\t<div class=\"elementor-container elementor-column-gap-default\">\n\t\t\t\t\t<div class=\"elementor-column elementor-col-50 elementor-top-column elementor-element elementor-element-2820cb8b\" data-id=\"2820cb8b\" data-element_type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t<div class=\"elementor-element elementor-element-9fb9997 elementor-widget elementor-widget-text-editor\" data-id=\"9fb9997\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<h1>Plunger cylinders: Maximum efficiency for linear actuators<\/h1><p>At their core, <a href=\"https:\/\/www.bf-hydraulik.com\/hydraulikzylinder.html\">hydraulic cylinders<\/a> consist of a pressure cylinder and a piston. The piston rod generally has a significantly smaller diameter than the force-bearing piston. In a <a href=\"https:\/\/www.bf-hydraulik.com\/en\/plunger-cylinder\/\" target=\"_self\" title=\"Plunger cylinders: Maximum efficiency for linear actuatorsAt their core, hydraulic cylinders consist of a pressure cylinder and a piston. The piston rod generally has a significantly smaller diameter than the&hellip;\" class=\"encyclopedia\">plunger cylinder<\/a>, the piston rod is almost as large as the cylinder&rsquo;s internal diameter and does not require an additional welded piston. Due to their design, <a href=\"https:\/\/www.bf-hydraulik.com\/en\/plunger-cylinder\/\" target=\"_self\" title=\"Plunger cylinders: Maximum efficiency for linear actuatorsAt their core, hydraulic cylinders consist of a pressure cylinder and a piston. The piston rod generally has a significantly smaller diameter than the&hellip;\" class=\"encyclopedia\">plunger cylinder<\/a>s are exclusively single-acting. Compared with double-acting cylinders, <a href=\"https:\/\/www.bf-hydraulik.com\/en\/plunger-cylinder\/\" target=\"_self\" title=\"Plunger cylinders: Maximum efficiency for linear actuatorsAt their core, hydraulic cylinders consist of a pressure cylinder and a piston. The piston rod generally has a significantly smaller diameter than the&hellip;\" class=\"encyclopedia\">plunger cylinder<\/a>s do offer advantages:    <\/p><ul><li>Simple design<\/li><li>More cost-effective to manufacture<\/li><li>More efficient<\/li><\/ul><p>The working piston of the <a href=\"https:\/\/www.bf-hydraulik.com\/en\/plunger-cylinder\/\" target=\"_self\" title=\"Plunger cylinders: Maximum efficiency for linear actuatorsAt their core, hydraulic cylinders consist of a pressure cylinder and a piston. The piston rod generally has a significantly smaller diameter than the&hellip;\" class=\"encyclopedia\">plunger cylinder<\/a> consists of a thick piston rod that is interrupted only by two seals. <a href=\"https:\/\/www.bf-hydraulik.com\/en\/plunger-cylinder\/\" target=\"_self\" title=\"Plunger cylinders: Maximum efficiency for linear actuatorsAt their core, hydraulic cylinders consist of a pressure cylinder and a piston. The piston rod generally has a significantly smaller diameter than the&hellip;\" class=\"encyclopedia\">Plunger cylinder<\/a>s are therefore quite robust, but can be manufactured more cost-effectively than double-acting cylinders. However, these cylinders also have disadvantages:  <\/p><ul><li>Limited functionality<\/li><li>More complex retraction<\/li><\/ul><p>A <a href=\"https:\/\/www.bf-hydraulik.com\/en\/plunger-cylinder\/\" target=\"_self\" title=\"Plunger cylinders: Maximum efficiency for linear actuatorsAt their core, hydraulic cylinders consist of a pressure cylinder and a piston. The piston rod generally has a significantly smaller diameter than the&hellip;\" class=\"encyclopedia\">plunger cylinder<\/a> is single-acting. To retract it, it must be acted upon by an additional external force, or alternatively the hydraulics can be switched from pressure to suction to return the <a href=\"https:\/\/www.bf-hydraulik.com\/en\/plunger-cylinder\/\" target=\"_self\" title=\"Plunger cylinders: Maximum efficiency for linear actuatorsAt their core, hydraulic cylinders consist of a pressure cylinder and a piston. The piston rod generally has a significantly smaller diameter than the&hellip;\" class=\"encyclopedia\">plunger cylinder<\/a> to its initial position. Along its force stroke, however, the <a href=\"https:\/\/www.bf-hydraulik.com\/en\/plunger-cylinder\/\" target=\"_self\" title=\"Plunger cylinders: Maximum efficiency for linear actuatorsAt their core, hydraulic cylinders consist of a pressure cylinder and a piston. The piston rod generally has a significantly smaller diameter than the&hellip;\" class=\"encyclopedia\">plunger cylinder<\/a> offers higher efficiency than other cylinders. This is reflected in greater force output or a smaller effective area. Due to its design and operating principle, the <a href=\"https:\/\/www.bf-hydraulik.com\/en\/plunger-cylinder\/\" target=\"_self\" title=\"Plunger cylinders: Maximum efficiency for linear actuatorsAt their core, hydraulic cylinders consist of a pressure cylinder and a piston. The piston rod generally has a significantly smaller diameter than the&hellip;\" class=\"encyclopedia\">plunger cylinder<\/a> is also referred to as a <strong>&ldquo;ram cylinder&rdquo;<\/strong>.      <\/p><h2>Applications of plunger cylinders<\/h2><p><a href=\"https:\/\/www.bf-hydraulik.com\/en\/plunger-cylinder\/\" target=\"_self\" title=\"Plunger cylinders: Maximum efficiency for linear actuatorsAt their core, hydraulic cylinders consist of a pressure cylinder and a piston. The piston rod generally has a significantly smaller diameter than the&hellip;\" class=\"encyclopedia\">Plunger cylinder<\/a>s are particularly useful where a counterforce is available virtually free of charge. A preferred installation orientation for these <a href=\"https:\/\/www.bf-hydraulik.com\/hydraulikzylinder-einfachwirkend.html\">single-acting hydraulic cylinders<\/a> is vertically upward. Since the <a href=\"https:\/\/www.bf-hydraulik.com\/en\/plunger-cylinder\/\" target=\"_self\" title=\"Plunger cylinders: Maximum efficiency for linear actuatorsAt their core, hydraulic cylinders consist of a pressure cylinder and a piston. The piston rod generally has a significantly smaller diameter than the&hellip;\" class=\"encyclopedia\">plunger cylinder<\/a> itself is extremely robust, at least the entire weight force of its piston is available as a counterforce.  <\/p><p>Hydraulic vehicle lifts are usually equipped with <a href=\"https:\/\/www.bf-hydraulik.com\/en\/plunger-cylinder\/\" target=\"_self\" title=\"Plunger cylinders: Maximum efficiency for linear actuatorsAt their core, hydraulic cylinders consist of a pressure cylinder and a piston. The piston rod generally has a significantly smaller diameter than the&hellip;\" class=\"encyclopedia\">plunger cylinder<\/a>s. The vehicle is raised by hydraulic force, but lowers again under its own weight. The example of the vehicle lift already makes it clear that the <a href=\"https:\/\/www.bf-hydraulik.com\/en\/plunger-cylinder\/\" target=\"_self\" title=\"Plunger cylinders: Maximum efficiency for linear actuatorsAt their core, hydraulic cylinders consist of a pressure cylinder and a piston. The piston rod generally has a significantly smaller diameter than the&hellip;\" class=\"encyclopedia\">plunger cylinder<\/a> is used only rarely for cyclical, productivity-focused applications. It is simply too slow for most applications.   <\/p><h3>Plunger cylinders in hybrid systems<\/h3><p>However, there is one exception in which the <a href=\"https:\/\/www.bf-hydraulik.com\/en\/plunger-cylinder\/\" target=\"_self\" title=\"Plunger cylinders: Maximum efficiency for linear actuatorsAt their core, hydraulic cylinders consist of a pressure cylinder and a piston. The piston rod generally has a significantly smaller diameter than the&hellip;\" class=\"encyclopedia\">plunger cylinder<\/a> can be used with maximum efficiency: in hydraulic-pneumatic <em>hybrid system<\/em><em>s<\/em>. If the <a href=\"https:\/\/www.bf-hydraulik.com\/en\/plunger-cylinder\/\" target=\"_self\" title=\"Plunger cylinders: Maximum efficiency for linear actuatorsAt their core, hydraulic cylinders consist of a pressure cylinder and a piston. The piston rod generally has a significantly smaller diameter than the&hellip;\" class=\"encyclopedia\">plunger cylinder<\/a> acts on a preloaded pneumatic pressure system, the counterpressure of the compressed gas can also be used to retract the pressure cylinder. This design is now more common in hydraulically driven work machines. Large material-handling machines from an Upper Bavarian manufacturer of industrial vehicles achieve fuel savings of up to 30% during operation with this functional principle.  <\/p><p>However, hybrid systems in which hydraulic and pneumatic components act on the same force system are very demanding in terms of design and maintenance. They are particularly hazardous and may only be handled by trained specialists. The greatest danger when working on hybrid systems is that even when the <a href=\"https:\/\/www.bf-hydraulik.com\/en\/hydraulic-pressure\/\" target=\"_self\" title=\"Hydraulic Pressure ExplainedPressure is generally a force acting on a surface. Hydraulic pressure is accordingly a force transmitted through a fluid that acts on the internal walls of a hydraulic&hellip;\" class=\"encyclopedia\">hydraulic pressure<\/a> has been relieved, the gases in the <a href=\"https:\/\/www.bf-hydraulik.com\/en\/piston-accumulator\/\" target=\"_self\" title=\"Piston accumulator: pressure provision without powerThe piston accumulator is a hydropneumatic component in hydraulic systems. It is used to provide pressure on demand without requiring an electrically driven pump. The&hellip;\" class=\"encyclopedia\">piston accumulator<\/a>s may still be under high pressure.  <\/p><h3>Emergency solution for plunger-cylinder retraction systems<\/h3><p>Another way to retract a <a href=\"https:\/\/www.bf-hydraulik.com\/en\/plunger-cylinder\/\" target=\"_self\" title=\"Plunger cylinders: Maximum efficiency for linear actuatorsAt their core, hydraulic cylinders consist of a pressure cylinder and a piston. The piston rod generally has a significantly smaller diameter than the&hellip;\" class=\"encyclopedia\">plunger cylinder<\/a> is to connect a second ram cylinder in parallel. When one cylinder extends, the other retracts. This simple but very space-intensive solution is therefore used only rarely. If no technically viable solution can be found, springs or electromagnets are also used to retract <a href=\"https:\/\/www.bf-hydraulik.com\/en\/plunger-cylinder\/\" target=\"_self\" title=\"Plunger cylinders: Maximum efficiency for linear actuatorsAt their core, hydraulic cylinders consist of a pressure cylinder and a piston. The piston rod generally has a significantly smaller diameter than the&hellip;\" class=\"encyclopedia\">plunger cylinder<\/a>s. However, both solutions are prone to faults, and electromagnets also require significant energy.    <\/p><p>Overall, using a <a href=\"https:\/\/www.bf-hydraulik.com\/en\/plunger-cylinder\/\" target=\"_self\" title=\"Plunger cylinders: Maximum efficiency for linear actuatorsAt their core, hydraulic cylinders consist of a pressure cylinder and a piston. The piston rod generally has a significantly smaller diameter than the&hellip;\" class=\"encyclopedia\">plunger cylinder<\/a> involves extensive planning and calculation.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t<div class=\"elementor-column elementor-col-50 elementor-top-column elementor-element elementor-element-17578f6\" data-id=\"17578f6\" data-element_type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t<div class=\"elementor-element elementor-element-18d5d30 elementor-widget elementor-widget-sidebar\" data-id=\"18d5d30\" data-element_type=\"widget\" data-widget_type=\"sidebar.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t<div style=\"display:none;\">Search<\/div><form role=\"search\" method=\"get\" class=\"encyclopedia search-form\" action=\"https:\/\/www.bf-hydraulik.com\/en\/encyclopedia\/\">\n    \n    \n    <label class=\"screen-reader-text\" 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