mh500 servo-hydraulic system

Y6/1-08V1.0

MH500 Servo-hydraulic System

Perfect combination of servo and solution

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1

Company profile............................................................... 2

MH500 Servo-Hydraulic System...................................... 3

Servo-Hydraulic System................................................. 4

Application Solution......................................................... 5

System Selection........................................................... 6

System Specification....................................................... 8

MH500 Servo Drives Specifications.................................9

MH500 Servo Drives Dimension.....................................10

Servo Motor Specifications.............................................12

Servo Motor Dimension..................................................14

System interconnect diagram.........................................16

Product characteristic curve chart...................................17

Energy-saving effect......................................................18

Successful Cases.........................................................19

System Configuration table..............................................20

Sales & Service Network.................................................21

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2

Company profile

Founded in 2005, INVT INDUSTRIAL TECHNOLOGY (SHANGHAI )CO.,LTD. (formerly Shanghai KINWAY

Technologies Inc.), is a Sino-foreign joint venture controlled by INVT (Stock Code: 002334). Incorporated by

several PhDs of outstanding achievements in automatic control returning from the United States, the Company

has successfully introduced the ten-plus years’ experience of renowned overseas large enterprises in

technological development and management to China, and developed into an enterprise with scientific and

technological innovation integrating research, development, production, sales and services; it has established two

subsidiaries, i.e. SUZHOU KINWAY and NINGBO JUNWEI. Since its foundation, the Company has been honored

as a Technology Pionerring Enterprise in Zhangjiang Hi-tech Park, Shanghai Hi-tech Enterprise, Shanghai

Innovative Enterprise and a Corporate Research and Development Institute in Pudong New Area.

Relying on its internationally advanced core technologies for permanent magnet simultaneous motor, power

electronics, digital control, sensor, network, field bus, ect., INVT has developed a series of high-end servo

systems and computer-controlled systems specially for equipment, with INVT and KINWAY (two brands of the

Company) products applied widely to plastic machinery, textile machines, oil fields, machine tools, industrial robots,

packing machines, electronic manufacturing and photovoltaic field.

The Company has been dedicated to using its leading servo drivers and automation technology to promote

the equipment manufacturing level and creating more value for the customers; it aspires to be a world-leading

industrial automation product and service provider that is respected by the people and trusted by the customers.

The company is striving to enhance the equipment manufacturing industry through leading servo drive and

automation technology, to create more value and competitiveness for customers.

MH500Servo-Hydraulic System

3

4

Servo-Hydraulic System

The accuracy of pressure sensor determines the control accuracy of

injection molding machines’operating pressure. Various accuracy

grade sensors could be customized to meet clients’demands.

Advantages of combining permanent magnet with reluctance motor, Its efficiency is

10%more than induction motor’s and its speed range is wider, compared with general

permanent magnet motor, Slender structure makes the dynamic response of motor faster

and noise lower , The special design of the air passage also makes the effect of motor

cooling more outstanding.

Deriving from the mature, stable and reliable hybrid electric vehicle motor controller,

and through rigorous electromagnetic compatibility, high low temperature, humidity,

vibration test and strong adaptability, all INVT servos have passed CE certification, and

development and production are standardized throughout the process for higher quality.

Adopting a high-performance resolver that can meet the requirements

of electric vehicles as position and speed feedback components, the

high-precision space vector field orientation control can be achieved

in the servo system. The solid structure, perfect ability of bearing high

temperature, anti-vibration and anti-interference can be adapted to the

harsh environment of injection molding machine. Accuracy is up to 4096

Pulses in each electric cycles, which is sufficient to meet the needs of

injection molding machine applications

Flow/pressure output

InstructionPressure(0～10V) Flow(0～10V)

CAN(optional) I/O(optional)

5

Application Solution

Injection molding machine

Die casting machine

Shoes machinery


6

Single Pump System

Multi Pump System

Complete portfolio of INVT servo-hydraulic system products provide servo systems of up to 55KW to meet the

supporting requirements of plastic injection molding machine of below 500T.

Able to drive oil pump of 25 ml/r ~ 160 ml/r and to supply flow of 50 L/min ~ 300 L/min.

Multiple pump flow-converging products realize coordination control of all subsystems through CANBUS of servo

controllers, put interflowed pressure as pressure feedback.

Given signals by upper-lever computer, the main servo controller, through CANBUS, transmits digitalized commands

to all other sub-servo controllers that have been set to optimized energy-saving levels based on their characteristics,

all sub-servo systems optimize the torque and speed control of the motors to guarantee the quick responses and the

stability of the system pressure and flow, as well as the smooth transition in all pumps. The multi pump flow-converging

control system can realize 16 linkages in a single hydraulic loop at most, which makes the maximum flow of the machine

up to 4000 L/min.

Single pump servo system

Driver+Motor+Pump+Parts Power supply

Speed feedbackPressure

Machineoil loop

Oil tankfeedback

P0-10V

Q0-10V

Othersignals

Motor

Servo system

cable

PC computer

Oil merger

7

Multi pump confluence control system

1. Multi pump control mode of the confluence wiring diagram

2. Multiple pump confluence system schematic diagram

Output

AIN3+

AIN3-

AGND

CRF

PE

GND

Power

Pressure sensor

System controller A/DAIN1+

AIN1-

AIN2+

AIN2-

AGND

AGND24V

+24V

ALM RST

S-ON

GND24V

ALM+

ALM-Alarm detection

Flow Output 0-10V

Pressure Output 0-10V

Failure reset

Drive Enable

CN15

6

9

11

1

2

3

4

15V Output

10

17

16

12

13

18

22

21CN6

1 2 3 4

1 2 3 4 1 2 3 4CN6 CN6

Master drive Slave drive 1 Slave drive 2

Slave Node

M

P

Follow Unit

M

Master Node

M

Pressure sensor

PP

Flow Instruction

Pressure Instruction

CAN CAN

Oil Output

Slave Node Slave Node

Master NodeSlave Node Slave Node


8

1. The composite pattern & multi-mode control system wiring diagram

2. Multiple pump composite pattern control system diagram

3. Multi-mode control system diagram

Composite patterns & multimodal confluence system

Slave Node

M

P

Independent units

M

Master Node

M

Pressure sensor

PP

Flow Instruction


CAN CAN

Oil Output 1

Pressure sensor Pressure sensor

Flow Instruction


Flow Instruction


Oil Output 2 Oil Output 3

Slave Node

M

P

Slave Node

M

P

Slave NodeSlave Node Master Node

Follow Unit Follow UnitControl UnitControl UnitIndependent

units

Slave Node

M

P

Slave Node

M

Master Node

M

Pressure sensor

PP

Flow Instruction


CAN CAN

Oil Output 1

Pressure sensor Pressure sensor

Flow Instruction


Flow Instruction


Oil Output 2 Oil Output 3

Control Unit Follow Unit Control Unit Follow Unit Independent units

AIN1 AIN2AOUT2 AOUT1 S_RDYI7 AIN1 AIN2AOUT2 AOUT1 S_RDYI7

Slave Node Master Node Slave Node

PT PT PT

CAN

CAN CAN

P2

Q2

C/D

S/ON

P1

Q1

C/D

S/ON

P3

Q3

C/D

S/ONS/ONS/ON

PT: Pressure Sensor

Q1-3: Flower Instruction

P1-3: Pressure Instruction

C/D:Confluence/shunt signal

S/ON: Drive enable

I7: Digital Input7 AIN1 AIN2: Instruction input

AOUT1 AOUT2: Analog Output S_RDY: Servo is ready

9

System Selection

34

rev/minin

Pump selection

Motor selection

Drives selection

Speed : the smaller value of maximum speeds of motor and pump

Known : maximum pressure and flow in hydraulic system

Select a motor has the rated torque equals to half as maximum torque



Please consult with INVT engineers to get optimized system configuration.


10

System Specification

Please consult with INVT engineers to get optimized system configuration.

Control mode Three-phase full-wave rectifier, IGBT PWM control, Sinusoidal current driven

Max. output frequency 400 Hz

Motor position sensor Resolver, resolution4096/rev

Runningconditions

Running/stroagetemperature

-20 ~ +55℃(≥45℃, derating)/-20 ~ +85℃

Humidity ≤95% RH(no condensation)

Air Indoor(no ditect sunlight), no corrosive gas, oil mist, flammable gas or dust

Altiude ≤2000m

Protection degree IP20

Cooling Forced air cooling

Digital

Input10 inputs: ①servo enable(S-ON) ②alarm clearance(ALM-RST) ②8 extemal control input interface(I1, I2, I3, I4, I5, I6, I7, I8)

Output4 outputs:①alarm output(ALM) ②ready(S-RDY) ③ control outputinterface 1 Relay output: double discharge pump output switching control(O1)

Analog

Input 43 inputs 10bitA/D (AIN1, AIN2, AIN3)

Output2 output 10bitD/A(ANOUT1, ANOUT2) can set the internalparameters output by LED panel or external HIMI

Power Output Provide 15V reference power

CommunicationCAN Communication with the host-computer, realize the parameter setting,

drive control, given command, the parameter saving functions.(When using the RS485 communication function, LED display panel and external HMI cannot be used)RS485

LED and keypad 5bit LED display, 5 function keys

External HMIExternal HMI communicate with Drives through RS485, realize the parametersetting, drive control, given command, and the parameter saving functions.

Control modeThrough the parameter setting, choosing one of the two control ways:①process control ②speed control

Control inputHydraulic control command input: analog input, CAN communication, orRS485 communication can be set Speed command input: CANcommunication or RS485 communication

Parallel multi-pump control Can control 16 pumps, three kinds of work mode(multi-pump, composite, multi-mode)

Precision of pressure control ±1bar(screw pump)

Precision of flow control ±0.5%FS

Pressure control step response ≤100ms given flow ＞ 70%(screw pump)

Flow control Speed step reponse ≤50ms feedback pressure is less than 10bar

Flow calibration function According to various features of the pump, calibrating the output flow

Speed command input RS485, CAN

Precision of speed control ±0.5%

Torque response time ≤2ms

Over-load capacity 180% rated current for 5 minutes, maximum output current for 30s

Software errorOver-current, DC over-voltage, DC under-voltage, braking resistordamaged, module over-temperature, pressure sensor failure, over-speedforward and reverse, brake over-load etc.

Software error Software failure, re-entry etc.

Alarm recording memory Can save 5 alarm recording memories

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MH500 Servo Drives Specification

Servo Drive Model

NO. Product brand

KT KINWAY

NO. Product series

CT Servo drive

NO. rated power output

7501 7.5kw

1502 15kw

1802 18kw

2502 25kw

3502 35kw

4502 45kw

5502 55kw

Drives Model KT-CT 7501-A 1502-A 1802-A 2502-A 3502-A 4502-A 5502-A

Applicable motor capacity [KW] 7.5 15 18 25 35 45 55

Rated output current [Arms] 25 37 45 60 75 90 123

Rated input current [Arms] 28 41 50 66 83 99 135

Max. output current [Arms] 45 66.6 81 108 135 162 283

Regenerative braking resistor 15Ω/500W 10Ω/ 1KWTwo 10Ω 2000w

Resistors connected in parallel

Input power 3-phase AC 323～475V±0%,45～65Hz±0%

NO. Cooling way

A Air cooling

B Oil cooling

NO. version number

0 Version 0

KT-CT 1502-A-0


12

MH500 Servo Drives Dimension

KT-CT-7501-A , KT-CT-1502-A , KT-CT-1802-A

KT-CT-2502-A

KT-CT-3502-A KT-CT-4502-A , KT-CT-5502-A

13

Servo Motor Specifications

Servo Motor Model

NO. Product brand

K KINWAY

NO. Product series

038 38Nm

More information, refer to the parameter table

NO. Cooling method

F forced air cooling

N natural cooling

Y liquid cooling

NO. flange dimension

18 180mm

25 250mm

05 52mm

NO. Rated seed

F 1800rpm

More information, refer to the parameter table

NO. Illustration

C Internal signature

NO. Axix type

P flat key

N internal spline

W external spline

G axis

Z taper

K-038 F 18 C 18 P


14

Servo Motor Dimension

39

200mm 280mm 180mm CE KTY84-130/Pt1000

200mm 280mm 180mm CE KTY84-130/Pt1000

200mm 315mm 180mm CE KTY84-130/Pt1000

200mm 315mm 180mm CE KTY84-130/Pt1000

72Nm 367V 1800rpm 2500rpm

72Nm 367V 2000rpm 2500rpm

72Nm 367V 2000rpm 2500rpm

91Nm 367V 1500rpm 2200rpm

200mm 210mm 180mm CE KTY84-130/Pt1000

200mm 210mm 180mm CE KTY84-130/Pt1000

200mm 245mm 180mm CE KTY84-130/Pt1000

200mm 245mm 180mm CE KTY84-130/Pt1000

38Nm 367V 1800rpm 2500rpm

36Nm 367V 2000rpm 2500rpm

58Nm 367V 1800rpm 2500rpm

58Nm 367V 1800rpm 2500rpm

arameters power ent voltageTor

speed speedWinding resistor

Winding

Model Model

Model Model

WeightCasing length Diameter

Pr Cooling method

Continuous S1

Continuous S1

Continuous S1

Continuous S1

Continuous S1

Continuous S1

Continuous S1

Continuous S1

Wmethod Cer



Winding

WeightCasing length Diameter Pr Cooling

methodWmethod Cer

PCD size

PCD size

Motor temperature sensor


39

200mm 280mm 180mm CE KTY84-130/Pt1000

200mm 280mm 180mm CE KTY84-130/Pt1000

200mm 315mm 180mm CE KTY84-130/Pt1000

200mm 315mm 180mm CE KTY84-130/Pt1000

72Nm 367V 1800rpm 2500rpm

72Nm 367V 2000rpm 2500rpm

72Nm 367V 2000rpm 2500rpm

91Nm 367V 1500rpm 2200rpm

200mm 210mm 180mm CE KTY84-130/Pt1000

200mm 210mm 180mm CE KTY84-130/Pt1000

200mm 245mm 180mm CE KTY84-130/Pt1000

200mm 245mm 180mm CE KTY84-130/Pt1000

38Nm 367V 1800rpm 2500rpm

36Nm 367V 2000rpm 2500rpm

58Nm 367V 1800rpm 2500rpm

58Nm 367V 1800rpm 2500rpm



Winding

Model Model

Model Model


Pr Cooling method

Continuous S1

Continuous S1

Continuous S1

Continuous S1

Continuous S1

Continuous S1

Continuous S1

Continuous S1

Wmethod Cer



Winding

WeightCasing length Diameter Pr Cooling

methodWmethod Cer

PCD size

PCD size



Specification PCD sizeCasing length

Flange Diameter

Weight Insulation ProtectionCooling method

Working method Certification Motor temperature sensor

K038F18C18P 200mm 210mm 180mm 36.2kg F IP54 Air cooling Continuous S1 CE KTY84-130/Pt1000




Electrical parameters

Ratedpower

Ratedtorque

Ratedcurrent

Ratedvoltage

Torque constant

Ratedspeed

Max.speed

Back-EMF constant

Winding resistor

Winding inductance

EMC/EMI

K038F18C18P 7.5kW 38Nm 12.9A 367V 2.97Nm/A 1800rpm 2500rpm 1.72V/s 0.700Ω 9.3mH IEC61800-3

K038F20C18P 7.5kW 36Nm 17.6A 367V 2.05Nm/A 2000rpm 2500rpm 1.19V/s 0.480Ω 6.5mH IEC61800-3

K058F20C18P 11kW 58Nm 20.0A 367V 2.90Nm/A 1800rpm 2500rpm 1.72V/s 0.410Ω 5.88mH IEC61800-3


Specification PCD sizeCasing length

Flange Diameter


Working method Certification Motor temperature sensor






Ratedpower

Ratedtorque

Ratedcurrent

Ratedvoltage

Torque constant

Ratedspeed

Max.speed

Back-EMF constant

Winding resistor

Winding inductance

EMC/EMI





15

SpecificationPCD size

Casing length

Flange diameter


Working method

CertificationMotor temperature

sensor

K187F18C25P 263mm 350mm 250mm 115.1kg F IP54 Air cooling Continuous S1 CE PT1000/PTC130/KTY84




K341F18C25P 263mm 578mm 250mm 196kg F IP54 Air cooling Continuous S1 CE PT1000/PTC130/KTY84


Rated power

Rated torque

Rated current

Rated voltage

Torque constant

Rated speed

Max. speed

Back-EMF constant

Winding resistor

Winding inductance

EMC/EMI

K187F18C25P 35kw 187Nm 74.6A 367V 2.58Nm/A 1800rpm 2500rpm 1.59 V/s 0.078Ω 2.3 mH EC61800-3



K239F18C25P 45kw 239nM 96.5A 367V2.70

Nm/A1800rpm 2500rpm 1.57 V/s 0.050Ω 1.6 mH EC61800-3

K341F18C25P 61kW 341Nm 155.3A 367V 2.20Nm/A 1800rpm 2500 rpm 1.42V/s 0.025Ω 1.17mH EC61800-3

Servo Motor Dimension

40

200mm 350mm 180mm CE KTY84-130/Pt1000

200mm 350mm 180mm CE KTY84-130/Pt1000

200mm 420mm 180mm CE KTY84-130/Pt1000

200mm 420mm 180mm CE KTY84-130/Pt1000

105Nm 367V 2000rpm 2500rpm

111Nm 367V 1500rpm 2200rpm

132Nm 367V 1800rpm 2500rpm

112Nm 367V 2200rpm 2200rpm



Winding

Model

Model Model

Model


Pr Cooling method

Wmethod Cer

Continuous S1

Continuous S1

Continuous S1

Continuous S1

PCD size Motor temperature sensor

40

200mm 350mm 180mm CE KTY84-130/Pt1000

200mm 350mm 180mm CE KTY84-130/Pt1000

200mm 420mm 180mm CE KTY84-130/Pt1000

200mm 420mm 180mm CE KTY84-130/Pt1000

105Nm 367V 2000rpm 2500rpm

111Nm 367V 1500rpm 2200rpm

132Nm 367V 1800rpm 2500rpm

112Nm 367V 2200rpm 2200rpm



Winding

Model

Model Model

Model


Pr Cooling method

Wmethod Cer

Continuous S1

Continuous S1

Continuous S1

Continuous S1

PCD size Motor temperature sensor

SpecificationPCD size

Casing length

Flange diameter


Working method

CertificationMotor temperature

sensor




K130F22C18P* 200mm 420mm 180mm 76.6kg F IP54 Air cooling Continuous S1 CE KTY84-130/Pt1000


Rated power

Rated torque

Rated current

Rated voltage

Torque constant

Rated speed

Max. speed

Back-EMF constant

Winding resistor

Winding inductance

EMC/EMI




K130F22C18P 25.8kw 112nM 54.0A 367V 2.40Nm/A 2200rpm 2200rpm 1.42 V/s 0.120Ω 2.0 mH EC61800-3


16

System interconnect diagram

41

Analog given 1 input +

Analog given 1 input -



feedback input+

feedback input-

Analog output1

Analog output2

Analog ground

Analog ground

given 10V reference power

fault reset signal

drive enable

programmable digital input1


control power input

digital signal ground


servo ready-

servo ready+

alarm output-

alarm output+

programmable digital input 2 output-

programmable digital input 2 output+

terminal no.

input and output signals

signal definitionPC codecolor shielded cable to the drive cabinet

pressure sensor

power supply redground black/blue

output green

HMI cable

lead wire

view direction of connecting terminals

the length of motor resolver cable is 2.5m

Motor resolver connection definition

Motor aviation plug connecting with control panelwiring identification wiring identification

blue

blue/white

green/white

white/orange

white

green

orange

excitation signal +

excitation signal -

resolver sine input +

resolver sine input -

resolver cosine input+

resolver cosine input-

the length of motor power cable is 2.5m

power cablebraking resistor

Motor power connection definition

Black

Black

Black

Black

Black

Black

Black

input filter

Input power supply

PE/grounding

gear pumps

bracket

motor

Auto Ru n

manual adjustmentforward

backwar d

Cancel Enter

Monitor Set Adjust





feedback input+

feedback input-

Analog output1

Analog output2

Analog ground

Analog ground

given 10V reference power

fault reset signal

drive enable



control power input



servo ready-

servo ready+

alarm output-

alarm output+

programmable digital input 2 output-

programmable digital input 2 output+

terminal no.

input and output signals

signal definitionPC codecolor shielded cable to the drive cabinet

pressure sensor

power supply redground black/blue

output green

HMI cable

lead wire

view direction of connecting terminals

the length of motor resolver cable is 2.5m

Motor resolver connection definition

Motor aviation plu g connecting with control panelwiring identification wiring identificatio n

blue

blue/white

green/white

white/orange

white

green

orange

excitation signal +

excitation signal -

resolver sine input +

resolver sine input -

resolver cosine input+

resolver cosine input-

the length of motor power cable is 2.5m

power cablebraking resistor

Motor power connection definitionBlack

BlackBlack

Black

Black

BlackBlack

input filter

Input power supply

PE/grounding

gear pumps

bracket

motor

Auto Run

manual adjustmentforward backward

Cancel Enter

Monitor Set Adjust

17

Product characteristic curve chart


1. Speed control features

2. Motor characteristic curve

3. servo drive system characteristic curve

Rated load when the motor speed accelerate from zero to

2500 r/min just 0.036 seconds

18

Energy-saving effect

Servo Hydraulic system energy-saving rate is determined by Dwell &Cooling time in the molding cycle. Normally the power consumption rate is between 20%~80%.

19


Successful Cases

Servo system for 850 tons plastic injection molding machine

Servo improvement of 250T plastic injection molding machine

Specification Conventional system Servo-Hydraulic System

Testing Time 263mm 350mm

Cycle Time 263mm 350mm

3hours Energy Comsuption 263mm 420mm

1day Energy Comsution 263mm 420mm

1year Energy Comsution 263mm 578mm

1year Energy Costs 35kw 187Nm

Energy Conservation 27kw 172Nm

Oil Temperature Rise 50kw 235Nm

Machine Noise 45kw 239nM

No.Product weight

Opening mould position(set 250)

Decompression value at end of injiection (set 0)

Decompression value at end of plasticizing (set 0)

1 234 290 31.5 190.7

2 234.5 298.4 31.3 190.6

3 234 298.3 30.5 190.7

4 234.5 298.9 30.8 190.7

5 234.5 298.3 30.9 190.4

6 234 298.3 30.6 190.6

7 234.5 298.3 30.8 190.6

8 234 298.5 30.9 190.6

9 234 298.3 30.8 190.5

10 234 298.4 30.6 190.4

Energy saving Test

Precision Test

Note: Translated at exchange rate 1US$=￥6.2233

KT-CT-2502-A-0

2*K235F18C25P2*125cc/rev

*

500L/min

K132F18C18P(25KW)

Save 41165(US$6614.7) in one year

80cc/rev

Drives 2*KT-CT-4502-A-0

System configuration table

Injection molding machine

Servo Retrofit configuration set System Features

S/NSystem Max flow （L/min）

System Max

pressure(bar)

Pump model

Servo motormodel/rated power

Servo driver model

Parts ListPump

capacity (cc/rev)

Motor rated torque (Nm) /rated speed

(rpm)

Driver rated

current (A)

K1 55 175 HG1-25-01 K036F20C18P/7.5KW KT-CT-7501-A-0

break resis-tor,bracket,cou-pling,pump de-livery port,pump

suction port,pressure sensor,power cable,resolv-er cable,fan cable,input reactance

25 36/2000 15

K2 70 175 HG1-32-01 K060F18C18P/11KW KT-CT-1502-A-0 32 60/1800 30

K3A 88 160 HG1-40-01 K072F18C18P/13KW KT-CT-1502-A-0 40 72/1800 30

K3 88 175 HG1-40-01 K072F18C18P/13KW KT-CT-1802-A-1 40 72/1800 35

K4 110 175 HG1-50-01 K078F20C18P/15KW KT-CT-1802-A-1 50 78/2000 35


K5 140 175 HG1-64-01 K132F18C18P/25KW KT-CT-1802-A-1 64 132/1800 35


K6 165 175 HG2-80-01 K132F18C18P/25KW KT-CT-2502-A-1 80 132/1800 53


K7 210 175 HG2-100-01 K239F18C25P/45KW KT-CT-3502-A-0 100 239/1800 75

K8 260 175 HG2-125-01 K235F20C25P/50KW KT-CT-4502-A-1 125 235/2000 95

K9 300 160 HG2-160-01 K341F18C25P/61KW KT-CT-5502-A-0 160 341/1800 135

20


21

Y6/1-08V1.0


Perfect combination of servo and solution

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mh500 servo-hydraulic system

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