Modular drive for economical forming technology

Bosch Rexroth: Industrial Hydraulics Modular drive for economical forming technology

2024-09-30 Source: Press Release | Translated by AI 4 min Reading Time

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The press manufacturer Dieffenbacher has developed a series of particularly efficient, economical, and flexibly configurable hydraulic presses. The modular industrial hydraulics from Bosch Rexroth contributed to meeting the requirements for minimal energy consumption.

Modularly economical, internationally competitive: Using largely standardized components, the manufacturer Dieffenbacher realizes a comprehensive series of hydraulic presses for sheet metal forming as well as shaping plastics and laminated wood.(Image: Bosch Rexroth) — Modularly economical, internationally competitive: Using largely standardized components, the manufacturer Dieffenbacher realizes a comprehensive series of hydraulic presses for sheet metal forming as well as shaping plastics and laminated wood.
(Image: Bosch Rexroth)

To form sheet metal as well as to shape glass-fiber-reinforced plastics and layered wood materials, the medium-sized family-owned company Dieffenbacher GmbH, Eppingen, has developed a series of hydraulic presses. This series includes variants with pressing forces ranging from 1000 kN to 10,000 kN. To manufacture the presses economically and remain competitive internationally, the specialists at Dieffenbacher consistently use modular components, particularly in the drive technology.

Together towards a modular drive concept

Georg Obermaier, head of the Business Unit Forming, explains the concept of the so-called Tailored Press from Dieffenbacher: "We wanted to build a future-ready press from standard modules that can be individually adjusted in terms of force, installation space, table size, and ram size. At the same time, we set high standards for energy efficiency. We found both aspects met with our system partner Bosch Rexroth, with whom we designed a modular drive concept that they ultimately were able to produce for us."

Gallery

Minimized energy consumption: Speed-controlled drives and demand-driven control of drive power from Bosch Rexroth are key components of the forward-looking concept for hydraulic presses.(Image: Bosch Rexroth)

Economical, flexible, and maintenance-friendly: The digitized hydraulic drive system from Bosch Rexroth, in conjunction with an accumulator control and hydraulic accumulators, requires only about 30 percent of the energy previously customary.(Image: Bosch Rexroth)

The modular drive concept enables the machine builder to easily implement the Tailored Press in various performance and speed classes. For instance, a version with 5000 kN press force can be simply converted to a speed variant with active high-speed parallelism for precise component thicknesses and higher component quality by changing to a different pump variant. For the entire range of press performance, Bosch Rexroth has suitable pump variants available. This ensures streamlined processes throughout the entire lifecycle of the presses, from engineering and inventory management to service. Additionally, other variants of presses, for example with drawing cushions, can be quickly realized as needed through the modular construction system of the drive technology.

Largely standardized

The drive modules for the current series of presses should consist of standard components as much as possible, aligning with the overall concept. For this purpose, the experts from Bosch Rexroth were able to provide their concept for the speed-controlled Power-on-Demand drive, innovative pump technology, and comprehensive know-how for installation and commissioning. Georg Obermaier comments, "Bosch Rexroth has an excellent reputation worldwide in the press industry. The company stands for continuity and good advice." Furthermore, Bosch Rexroth has a production facility for drive technology in Brno, Czech Republic, which is regionally close to the press manufacturer's operations.

Demand-oriented flow rates

For the main drive, press manufacturers use their modular concept axial piston variable pumps A4VSO in various nominal sizes with digital control device HS5, and the press module IH04 with a standardized safety concept and EC type-examination certificate for Performance Level e Category 4 according to the requirements of DIN EN ISO 16092-3 and DIN EN 289.

Control and cooling circuits with water cooling are constructed from functionally equipped manifold plates and motor-pump units with axial piston variable pumps A10VSO. Bosch Rexroth provides the speed-controlled hydraulic unit corresponding to the respective press design as a component of a complete package.

The electro-hydraulic drive concept generates volume flows as needed. This is achieved through the swivel angle of the axial pumps and the motor speed. The pumps can operate at 1.5 times the power when needed. A digital control system precisely adjusts the volume flows to specific process points. When no power is required, the pumps are turned off. At these times, the presses require virtually no energy.

70 percent less energy

Compared to conventional drives that operate at constant speeds, the optimally controlled electro-hydraulic press drives require only about half the energy. Together with adaptive accumulator control, the energy requirement can be reduced to about only 30 percent. The directly driven hydraulic presses automatically adjust the charging pressure of the hydraulic accumulator in anticipation of upcoming forming processes. For the operating personnel, familiar workflows and processes are retained. Forces, paths, and ram parameters are set as before, with the respective speeds automatically calculated by the drive control.

Digitalization simplifies service

Also in terms of advancing digitalization, the innovative drive concept proves to be advantageous. Thanks to integrated interfaces, the press manufacturer can equip particularly economical machines with its digitalization platform, Evoris. This enables the integration of cutting-edge online services even in the individually customized presses of the current series. This includes remote maintenance, condition monitoring, and data-based analyses for process improvements and predictive maintenance. Thus, the manufacturer simplifies and accelerates its global service, which in turn benefits users as they can minimize downtime and optimize the use of the presses.

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Economical, flexible, and quiet

As Georg Obermaier reports, the partnership with the drive technicians from Bosch Rexroth is an important step towards standardization, flexibility, and economic efficiency. "In addition to energy efficiency and digitalization, the drive technology also impresses in terms of compact construction and noise emission. Our requirement of a maximum 80 dbA sound pressure was significantly undercut with an actual 70 dbA."

“This article was first published on our sister portal
"SMM Schweizer MaschinenMarkt" (German Edition), Vogel Communications Group.“

(SME)