Servo Presses | Plastic Forming | Introduction to Machining

1. Overview and Characteristics

Controlling the speed of a pressurization unit and the pressurization count of a press was considered difficult with conventional machines. However, with the emergence of the servo press in the s, complex press control became possible through the adoption of CNC and servo motors. With a servo press, operators can set the processing speed, position, and pressure using numerical values.
For example, when stamping sheet metal using a complex die, if the processing speed is constant, excessive force may be applied to certain parts of the sheet metal, resulting in poor forming. For this reason, the processing speed was decreased with conventional presses to carefully stamp the materials, which hindered productivity.
The servo press works around this problem by driving the press at high speed mid-way through the stamping motion and lowering the speed close to the bottom dead center (bottommost point of pressurization). This consequentially offers both improved yield rate and productivity.

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1. What is a Servo Press Machine?

Servo press machine usually refers to presses that are driven and controlled by servo motors. They include servo presses for metal forging and servo presses for industries such as refractory materials. Due to the numerical control characteristics of servo motors, they are sometimes widely referred to as CNC presses.

The servo press machine uses a servo motor to drive the eccentric gear to achieve the movement of the slide. Through complex electrification control, the servo presses can arbitrarily program the slide stroke, speed, and pressure, and even achieve the nominal tonnage of the press at low speed.

2. What Are the Classifications of Servo Presses?

Servo presses are divided into servo crank presses, servo connecting rod presses, servo screw presses and servo hydraulic presses.

2.1 Servo Crank Press

The mechanical crank presses, the eccentric gear drives the slider crank to move up and down, and the curve is a sine curve. Generally, the maximum nominal tonnage is reached before the slider moves to the bottom dead center. The stroke is fixed and cannot be adjusted. Hydraulic presses use liquid to transmit pressure so that the engineering tonnage can be achieved at any position of the slider stroke. The stroke is adjustable but the efficiency is low.

The servo press machine controls the movement of the slider through a motor and combines the advantages of mechanical presses and hydraulic presses through pre-programming. It can realize any type of stamping production at any stage of the stroke, and the pressure curve can be arbitrarily programmed.

2.2 Servo Screw Press

In the traditional double-disc friction drive screw press, the friction disk rotates continuously after the machine is started, which consumes a lot of energy. The impact force is greatly affected by human factors, and the product quality is unstable.

As upgraded equipment of friction press, in the fields of hot forging and refractory material forming processing, two types of electric screw presses, switched reluctance screw press and servo screw press, have appeared on the market according to the different driving motor.

After the servo screw press is started, the motor will stop immediately as soon as the control voltage is lost. Therefore, the power consumption of the press other than when it is striking is almost negligible, which saves about 60% of electricity compared to a friction press. In addition, due to the superior performance of the servo motor, the servo screw press runs more smoothly and accurately and can achieve rapid striking within an ultra-short stroke.

3. What Are the Application Areas of Servo Press Machine?

• Refractory industry: Forming of refractory bricks, special-shaped refractory bricks and refractory balls.

• Automobile industry: engine assembly press-fitting (cylinder head, cylinder liner, oil seal, etc.), steering gear assembly press-fitting (gear, pin, etc.), transmission shaft assembly press-fitting, gearbox assembly press-fitting, brake disc assembly, etc.

• Motor industry: press-fitting of micro-motor components (spindle, housing, etc.) and motor components (bearings, spindle, etc.).

• Electronics industry: circuit board assembly press-fitting (plug-ins, etc.), electronic parts.

• Home appliance industry: home appliance accessories, home appliance accessories riveting, etc.

• Mechanical industry: mechanical parts, automated assembly lines, lifespan testing of wearing parts, etc.

4. Servo Press Machine Market Development Trend

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The global servo press machine market size is expected to reach USD 1,068.3 million by , growing at a CAGR of 4.8% from to . Servo presses are used in processes such as forging, stamping, forming, and metal forming. Servo presses are equipped with high-performance servomotors that provide higher slide rates during the forming process than conventional hydraulic presses.

The growing population in the Asia Pacific region and the steady growth of economies such as India, China, Mexico, and Bangladesh have led to rapid urbanization, which is expected to boost the industrial sector and, in turn, is expected to increase the demand for servo presses. The Asia Pacific region is emerging as a major automotive hub due to the rapid growth of the automotive industry in countries such as China and India.

China is the world's largest automotive market, both in terms of manufacturing capacity and annual sales, while India has about 25 cars per thousand people as of , a number that is expected to exceed 150 by . In addition, the Indian home appliances and consumer electronics industry is expected to reach $21.28 billion by , and the installation of indoor air conditioners is expected to increase from 30 million units in to 124 million units by .

Therefore, the demand for servo presses in the Asia Pacific region is expected to increase significantly. However, the high initial cost of new equipment, the high adoption of second-hand servo presses, and the volatility of raw material prices have hampered the growth of the servo press market.[1]

5. What are the Advantages of the HONEST Equipment Servo Press?

The penetration rate of the domestic servo press market is less than 20%, and high-end equipment is highly dependent on imports. With mature electrical experience and technical advantages, HONEST Intelligent focuses on customer needs and actively promotes the penetration rate of servo presses at home and abroad.

HONEST Intelligent servo press machine solution integrates servo drive and pressure controller to achieve high-precision control of speed, pressure closed loop and position closed loop during the pressing process. At the same time, it monitors and judges the production data.

Functional Advantages:

• High flexibility: supports 64 steps of free programming, and all pressing actions can be arranged and combined arbitrarily.

• Convenient interaction: Compatible with IO control and Modbus communication control, convenient for interaction with external devices to achieve action synchronization or action interleaving.

• Simple operation: Graphical interaction is carried out through the touch screen/host computer software, and the threshold for use is low.

• Fully functional: Built-in data acquisition, curve detection, sensor calibration, position closed-loop and other functional modules can meet the vast majority of press fit scenarios.

Performance Advantages:

1. Excellent precision: positioning accuracy 0.01mm, pressure accuracy 5&#;FS.

2. Efficient pressure building: The pressure can be built from 0kgf to more than kgf within 1S at the fastest, and the overshoot doesn't exceed 5&#;FS.

3. The equipment responds quickly: the sensor is directly connected to the servo drive, and the closed-loop link is short, which improves responsiveness from the root.

HONEST Intelligent new servo press machine is designed to meet your stringent requirements for high precision and intelligence. We have successfully helped many customers achieve production upgrades. We will customize the best solution for you and provide a detailed quotation, welcome to consult now!

[1] Data source: Allied Market Research

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