Servo Press Machine: Ultimate Guide

Forming presses have evolved over the years, and servo press machines have also been developed for a long time. In this article, we will detail some common problems with servo press machines.

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What is a Servo Press Machine

servo press machines usually refer to presses that use servo motors for drive control. This includes servo press machines for metal forging and servo press machines for refractory materials and other industries. Because of the servo motor's numerical control characteristics, it is sometimes widely referred to as a CNC press.

servo press machines drive eccentric gears through a servo motor to realize the slider movement process. Through complex electrification control, the servo press machine can be programmed with arbitrary ram travel, speed, pressure, etc. to achieve the nominal force of the press even at low speed operation.

Servo Press Machine Classification

Servo press machines are classified into servo crank presses, servo link presses, servo screw presses, and servo hydraulic presses, etc.

• Servo crank presses

  The general mechanical crank press is driven by eccentric teeth to move the slider crank up and down and the curve is a sine curve. The nominal force is generally reached before the ram runs to the lower stop. The stroke is fixed and non-adjustable. The general hydraulic press can achieve the nominal force at any position of the ram stroke because the pressure is transmitted by liquid. The stroke is adjustable but inefficient.

  Servo press machines, on the other hand, control the movement of the ram by means of a motor and combine the advantages of mechanical presses and hydraulic presses by means of pre-programming, so that press production can be realized in any way at any stage of the stroke and the pressure curve can be programmed at will.

• Servo screw presses

  The conventional double-disc friction-driven screw presses continuously rotate the friction discs after starting the machine, which consumes a lot of energy, and the striking force is subject to human influence, making the product quality unstable.

  As an upgrade of the friction press, in the field of hot forging and refractory molding processing, two kinds of electric screw presses, the switch reluctance screw press and the servo screw press, have appeared in the market according to the different driving motors.

  Servo screw presses start the machine, as soon as the control voltage is lost, the motor immediately stops, so the power consumption is almost negligible in the time other than the press implementation of striking action, saving about 60 percent of power than friction presses, and due to the superior performance of servo motors, servo screw presses run more smoothly and can achieve fast striking within a very short stroke.

  1. Refractory material industry: refractory bricks, shaped refractory bricks and refractory balls molding.

  2. Automobile industry: engine component press (cylinder head, cylinder liner, oil seal, etc.) steering component press (gear, pin, etc.) transmission shaft component press, gear box component press, brake disc component, etc.

  3. Motor industry: micro-motor component press-fitting (spindle, housing, etc.) motor components (bearings, spindles, etc.)

  4. Electronics industry: circuit board components press-fit (plug-in, etc.), electronic components.

  5. Home appliance industry: home appliance parts, home appliance parts riveting, etc.

  6. Machinery industry: mechanical parts, automatic group line, wear parts life test, etc.

• Servo hydraulic press

  Servo hydraulic press is used to drive the main drive oil pump by servo motor, reduce the control valve circuit, and control the hydraulic press slide, which is suitable for stamping, die forging, press fitting, straightening and other processes. Compared with common hydraulic presses, servo-driven hydraulic presses have the advantages of energy saving, low noise, high efficiency, good flexibility and high efficiency, and can replace most of the existing common hydraulic presses.

Servo Press Machine Structure and Composition

The structure of servo press machine has table type C, bow type, single column type, two column type, three column type and four column type. The table type structure is simple and reliable, with strong load-bearing capacity and small load-bearing deformation, which is a stable and widely used load-bearing structure. The main system of the equipment consists of servo motor, motor controller, reduction drive, brake, position sensor, programmable controller, touch screen, working mechanism, auxiliary mechanism, etc.

Servo press machine structure and technical characteristics

• The main structure

  The use of table structure, simple and reliable, strong bearing capacity, bearing deformation is small, is stable, the use of a wide range of bearing structure.

• Servo press machine system composition.

  Equipment primary system composition: servo press machine unit, control system, display and other components.

  servo press machine principle: servo motor drives fine ball screw through synchronous belt to complete the pressure spindle orientation control; pressure spindle front-end equipment high sensitive pressure sensor, can real-time detection of pressure spindle load; control system real-time collection of orientation and load data, so as to complete the fine press online quality management technology.

• Servo press machine fitting unit primary components.

  Drive equipment --- servo drive

  Transmission equipment --- synchronous wheel structure, fine ball screw

  Pressure output --- pressure spindle

  Bearing sets --- ball bearings, self-lubricating bearings, etc.

  Pressure sensor --- external type, beautiful structure, no interference of electric wire

  Housing --- sheet metal spray paint

  Control system --- closed loop control

Application status of servo press machines

Screw presses can be used in many industries, forging industry, resistant material industry, etc.  In recent years, with the development of science and technology, the market demand for high-quality, high-precision, low-priced products is growing, and the demand for processing equipment for manufacturing products is becoming more and more abundant, thus making the international competition in the manufacturing industry more and more intense.

The structural characteristics of servo press machines are:

1. Small structure, light weight, functional compounding and integration.

2. Extend the life of components and improve the reliability of the system.

3. Reduce hydraulic vibration and noise.

4. Combined with electronic technology to improve the control capability.

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Since servo press machines have many advantages that cannot be surpassed by traditional presses. At present, Japanese enterprises in the new presses, 99% is to purchase servo press machines, it can be seen that the future servo press machines will definitely replace the traditional presses and become the core of plastic processing equipment.

Analysis of the development trend of servo press machines

servo press machine development history, servo press machines are widely used in developed countries, Japan AMINO (AMINO), Japan Komatsu (KOMATSU), Germany SCHULER (SCHULER) and other press manufacturers have launched a variety of transmission structure, different specifications of the servo press machine, almost monopolizing the market of all high-end presses, access to huge economic benefits. However, due to the rapid growth of the national economy, the internationalization of the market and the rise of people's consumption views, the streamline and personalized requirements for manufacturing products, various industries have also introduced a lot of foreign manufacturing equipment. Due to the high precision and good working environment of the manufactured products of servo press machines, and also the advantage of energy saving, which is more meaningful to the current domestic saving society, it is bound to be recognized and widely used in the near future, and it is also believed that it will replace the existing presses in the forming field in the near future. servo press machines are developed from the following aspects.

What are the issues to consider when choosing a servo press machine?

1. The first thing to look at the servo press machine precision is not high. Precision refers to the accuracy of the pressure and position to reach a specific point to stop. He is related to the resolution of the drive, the resolution of the pressure transmitter, the accuracy of the servo motor and the response speed of the response equipment. servo press machine through the mature set of servo motor and drive integrated control, its repeat accuracy is getting higher and higher, the use of a wider and wider range, if you need high precision servo press machine, choose servo press machine will focus on the configuration

2. The second look at the structure of the servo press machine and servo press machine manufacturers of the general structure is not a single, common four-column, single column, arch, horizontal, frame hydraulic press, four-column economical and practical structure, single column, arch structure is easy to operate, the level of operation found in the longer than other products, frame type in the large tonnage dominant, so the choice of structure still needs to be based on product size and structure

3. Servo press machine functions include forging, stamping, assembly, assembly, pressing, forming, flanging, shallow pulling, etc., different functions often have different structures, so you also need to choose the right servo press machine according to their own circumstances. Product process requirements

Selecting an excellent servo press machine manufacturer

Electromechanical servo press technology uses less energy than pneumatic or hydraulic assembly systems since they only draw current on demand – an energy reduction of 70-90 % is feasible with the electromechanical approach. As servo presses become more prevalent for joining processes, it is important to understand the different measurement technologies available and which technologies are most appropriate for your assembly process.

During a joining operation where an interference fit occurs, a signature force vs. displacement curve is generated.

Here are the key technologies and considerations when selecting an electromechanical servo press solution:   

Position Measurement Technologies

LVDT. External to press system: Voltage signal (analog) could be less resolute than other approaches, but is less expensive.

External and incremental encoder: May cost extra engineering effort to select and design a strategy to measure from external encoder. Must be rehomed at startup after power outage

Internal Absolute Encoder: Best resolution and repeatability specifications. The press manufacturer selected an encoder matched to their provided motion controls system, and can also use this sensor for closed-loop control of the electromechanical servo press system.

Force Measurement Technologies

Torque derived from motor amplifier: Not as resolute as a sensor placed directly in the axis of force, since it is derived. Least expensive hardware approach, since no external sensor is required. Repeatability may not be satisfactory. This approach may require an external software or PC to analyze the motor torque data.

Strain Gage: Ideal for static processes, where pressing and holding is required - for instance, where a part must be held at a constant force while a robot welds the part in place. Strain gages yield nonlinearities in the low end and are susceptible to hysteresis – permanent mechanical deformation.

Piezoelectric: Ideal for dynamic processes and low force requirements, such as measuring when a plastic part snaps into position. Advantage of dual measuring ranges for flexible assembly stations where the measurement is extremely linear across the entire force range. Piezoelectric sensor characteristics are stable over time and temperature and do not require external excitation to function.

Strategies for Analyzing Live Data

PC-based analysis system: PCs are widely available and are relatively inexpensive. However, they are susceptible to IT policies, updates and malware – which can interfere with production systems. PCs are ideal for offline data analysis.

Embedded analysis system: Embedded computing systems designed for industrial use are the types of computers that should be on the plant floor. For 24/7 uptime manufacturing operations, a deterministic embedded computer should be used for data analysis and live signal processing. An embedded system evaluating live force/displacement data can even help to identify manufacturing flaws while the parts are being formed – saving cycle time and capturing non-nominal parts further upstream.

Strategies for Analyzing Offline Curve Data

Production software: Generally a large modular platform that can encompass all operations on a plant floor. May be integrated into production or quality systems but usually delivered with a hefty price tag.

Math software: More generic; a 3rd party developed open architecture platform that may be customized but requires extensive knowledge to program and maintain.

Vendor Developed Software: Supplied by press provider generally offers a user friendly application specific platform that offers powerful visualization and analysis of processes but is not easily customized.

Mechanical Considerations

The mechanical modules have two main components: servo motor and a linear screw. The motor mounting configuration comes in 3 varieties where the screw is limited to two types. There are advantages for each but some systems offer far greater benefits when compared to other types.

Integrated servo motor: Direct-driven; provides a stiff connection with no belt wear or backlash and requires less maintenance. Very compact in size compared to an externally mounted motor of equal force.

Externally mounted coupled servo motor: Direct-driven; provides a stiff connection with no belt wear or backlash and requires less maintenance

Externally mounted belt driven servo motor: Drive belts provide a point of failure and position accuracy due to belt wear or backlash. Drive belts require additional steps for maintenance crews for inspection and tightening.

Ball screw vs. planetary roller: Both are well-suited for most joining and press fit applications. The planetary roller can handle much higher loads with the same motor size due to the load is distributed over a greater contacting surface area. This reduces heat, increases efficiency and extends longevity.

Kistler Type B… NCFH Joining Module with hollow shaft motor

Global support and service

Representatives vs. Direct engineers: If the assembly station will ship to another country for production, it is important to consider the support structure in place in this geography. Press manufactures either sell systems directly or use a network of representatives to handle technical support and replacement parts in these locales. Dealing direct with the manufacturer often yields the best technical support and product availability.

Contact your local Kistler representative or visit our website www.kistler.com.

Kistler Instrument Corp.

Hudson Drive

Novi, MI

. + 1 248 668

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