Komatsu engineering&#;has combined today&#;s modern A.C. servo technology into mechanical press design to provide a versatile, efficient and reliable solution to the changing demands of today&#;s pressroom, which incorporates a standard catalog listed servo motor from a proven motor and control system manufacturer. No proprietary servo motors or servo motor controllers are used. The main gear and drive pinion gear have helical cut gear teeth. Shaft connection to the main gear is by spline cut teeth, not a taper key and key way. The crankshaft is supported by bearings before (front) and after (rear) the pitman connection cap and at the driven end of the shaft with the main gear.
Click here to get more.
A Linear Scale is mounted to the frame of the press and monitors the slide position to assure repeatable die height consistency at the bottom of the stroke where the work is being done. The linear scale is mounted to a sub-frame, fixed at the bottom to assure slide position accuracy and allowed to &#;float&#; at the top while the press frame is under load.
When selected by the user, the linear scale continuously monitors the slide position to assure consistent die height (slide face to bolster top). The two (2) strain gauges of the electronic load monitor system read the tonnage applied every stroke. As both the linear scale and strain gauges send data to the control, the operator can select to either control the die height or the applied tonnage. Die height adjustments and tonnage settings are automatically made during the continuous mode operation of the press.
Constant pressurized flow of oil reaching the bearings, journals, and gibs, which then flows into a recovery tank equipped with dual filtering before reuse.
Komatsu AC servo technology. Dual timing belts are used to couple the servo motor to the drive train, which are constantly monitored electronically for motion and breakage. The belts help to isolate the servo motor from the reverse shock (snap through) inherent to stamping blanking type operations.
A manual pulse control is mounted on the front side of the operator &#;T&#; stand for use in the Jog mode of operation. This control allows the operator to &#;micro-step&#; the slide stroke motion, in either the Up or Down direction. Useful in initial die tooling set up, and process verification. The manual pulse control is used in conjunction with either one of the run buttons to maintain the &#;Two Hand Control&#; operation requirement for the operator.
Helps to prevent damage to the press and dies. All Komatsu presses are equipped with a hydraulic overload protector, a standard feature that has been a Komatsu standard for decades helping to protect against damage to the press or tooling. If the rated load of the press is exceeded at BDC (Bottom Dead Center), the press stops automatically. The hydraulic pressure can also be manually released easily, to allow operations to resume quickly if part jamming occurs.
Advanced electronics technology provides user-friendly operation and outstanding reliability. The SIT IV electronic press control unit is designed to provide the fastest, easiest, and most reliable control available for all press functions. Included as standard equipment on the Komatsu H1F press, the SIT IV incorporates all the latest thinking in press control unit design.
Digital display for improved operation performance. Digital display of the crank angle and electronic angle detectors provide increased accuracy for press operations. Operation setting and die set-up functions are easier and faster for press operators, with precise, reliable settings every time. To protect the integrity of all electronic systems and provide additional safety, monitor lamps indicate functionality status of the control circuits and if detected, &#;fault&#; messages are displayed on the HMI screen.
Introduction
In a hydraulic press, hydraulic fluid is pumped and pressurized to create the desired force, speed, and motion of the ram and any ancillary equipment (shuttles, knockout cylinders, booking rams, etc.). Conversely, a servo-electric press uses individual electro-mechanical (roller screw or ball screw style) actuators and servo motors / drives to perform each desired operation within the cycle.
While much has been written about the benefits of servo-electric presses, they are not always the best solution. Both forms of actuation have strengths and weaknesses, and choosing the right one for your application depends on a number of factors. This whitepaper explores the primary differences between the two technologies and offers recommendations for successful implementation based on the factors most important to you.
Position & Force Control
Both hydraulic and servo-electric presses have fully adjustable stroke profiles and can achieve maximum pressing force at any point throughout the stroke. This allows you to program the machine to adapt to different tool shut heights and perform &#;short cycle&#; strokes when desired (in a coil-fed punching application, for example), while also maintaining the flexibility to be used in deep draw or powder compacting applications.
Programmable electro-mechanical actuators ensure accuracy and positional repeatability to within +/- 0.&#; and force control to within +/- 0.5% or better. They also offer instant feedback for diagnostics and maintenance, as well as built-in data acquisition to record and measure torque, force, position, speed, and time at a rate of 1 sample / ms.
While the accuracy of hydraulic systems has improved (both from a position and pressure control standpoint) due to the increased use of proportional/servo valves and high-speed motion controllers, applications requiring high precision and force control are still better suited for a servo-electric press.
Tonnage Requirements
Currently, most electro-mechanical actuators are limited to approximately 50 tons of force each. Although they can be arranged in series to accommodate higher-tonnage applications, groupings are typically limited to four because the increased component cost as well as the increased space required within the press&#; footprint to accommodate multiple actuators often aren&#;t realistic for most manufacturers. For this reason, applications which require force beyond 200 tons are typically better suited for a hydraulic press.
Due to the inherent flexibility of a fluid power system, hydraulic presses can be easily scaled to accommodate both low and high-tonnage applications without greatly impacting the overall footprint.
With competitive price and timely delivery, S-T Intelligence sincerely hope to be your supplier and partner.
Forming Flexibility
Some applications require more flexibility in their forming equipment than others. For example, are you developing a new, cutting-edge manufacturing process or forming a new material? Are you working in a lab or clean room environment or a high-end manufacturing facility? If so, you do not want to be limited by traditional hydraulic equipment. Servo-electric presses are the most flexible, highest performing, and cleanest machines available today.
While the cost of electricity in many locations has doubled or tripled over the last decade, so has the number of companies implementing green initiatives to reduce energy consumption, emissions, and other forms of pollution.
A large amount of electricity is required to power a hydraulic system, even when the press is idle. Some energy-efficient technologies like variable frequency drives (VFDs), pneumatic dwell systems, and soft starters are available for hydraulic presses, but even with these features, hydraulic presses still consume significantly more energy than their electro-mechanical counterparts. Servo-electric presses, however, only use energy on-demand, yielding a 20-50% energy savings depending on usage and duty cycle.
Because servo-electric presses run entirely on electricity, oil is not required. Not only does this reduce the number of components needed to run the system, it eliminates costly leaks and disposal fees and ensures that cleanliness requirements are maintained for meticulous environments like labs, clean rooms, and food processing plants.
Motors and pumps that drive a hydraulic power unit can exceed 90 decibels. By eliminating the HPU and its components and only using power when the press is operating (on-demand), servo-electric presses maintain a very low ambient noise level, virtually eliminating noise pollution. On average, noise levels are typically 30% lower with servo-electric systems.1
Maintenance
The best way to prevent unplanned downtime with any piece of forming equipment is to follow its factory-recommended preventive maintenance schedule with internal personnel, or hire the OEM under a service contract to perform the maintenance for you. For hydraulic presses, this includes performing oil changes, checking and replacing hydraulic lines and fittings, maintaining oil cleanliness, monitoring particulate counts, and reviewing press performance data to uncover inefficiencies. If your facility has in-house maintenance personnel familiar with the on-going needs of a fluid power system, these tasks can be relatively simple, inexpensive, and routine.
However, if your maintenance team is less experienced with hydraulics or you don&#;t have in-house maintenance capabilities, a servo-electric press is the better choice. Servo-electric presses require very little maintenance over time. Without oil tanks, pumps, valves, and hoses, servo-electric presses require fewer components to achieve force. This makes them much easier to maintain and support compared to hydraulic or mechanical flywheel systems. Additionally, quick-connect cables on servo-electric presses install in a fraction of the time it takes to plumb a hydraulic system and are frequently used in &#;plug-and-play&#; environments.2 Depending on the application and duty cycle, they can go 15 years or more without performing any factory recommended maintenance.3
Cost of Acquisition vs. Cost of Ownership
Typically, hydraulic presses have a lower upfront cost of acquisition than servo-electric presses, so the savings from lower operating costs and improved part quality long-term are often overlooked on servo-electric machines. The amount of time it takes to achieve full ROI on an electro-mechanical system will vary depending on your application, usage requirements, and utility costs, but it is not uncommon to see payback in as little as one year.4
Due to their high accuracy and advanced data acquisition capabilities, servo-electric presses can also be used to perform &#;in-press&#; quality checks. The ability to verify part quality during the cycle often allows a downstream quality check to be eliminated and should be factored into ROI calculations for this technology.
In a fluid power system, one pump and reservoir can power multiple actuators. This results in additional upfront cost savings for applications which require ancillary operations like knockout cylinders, draw cushions, shuttles, clamps, etc.
If upfront cost is most important to you and/or you have multiple ancillary operations within your cycle, then a hydraulic press is the best choice. If long-term energy savings and improved part quality are your deciding factors, then a servo-electric press is the best choice.
Safety
Operating temperatures on a hydraulic press are much higher than servo-electric due to the nature of hydraulic fluid which heats up when it&#;s being pumped throughout the system. If not cooled properly, this could cause premature component failure. When a high-pressure hose leaks or bursts on a fluid power system, it creates an unsafe work environment for the operator and maintenance staff.
When performing applications that require heated platens (hot forming, SPF, compression molding, etc.), servo-electric presses are the safer choice. Since oil is not required to generate force in an electro-mechanical system, it is much less of a fire hazard when working with increased temperatures.
Conclusion
Whether you&#;re developing a new forming process or you simply want to improve an existing one, choosing the right equipment is paramount to your success. Both hydraulic and servo-electric presses offer a variety of advantages and disadvantages that could be the deciding factor for your purchase. Before choosing any kind of press, it is important to understand your production goals, application requirements, safety objectives, maintenance capabilities, and efficiency standards and choose an OEM that can customize the machinery to meet your exact needs.
References
For more Double point servo press for saleinformation, please contact us. We will provide professional answers.