Tank Plate Systems Nitrogen Instead of Hydraulic Oil Provides a Boost in Forming

Related Vendors

Steinel Normalien AG

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Nitrogen systems can be efficiency boosters for modern press shops.

Wrinkles and cracks, uneven transitions, burst contours—common defect patterns in press shops, usually caused by inadequately controlled forming processes.

The adage "more is better" often results in more force being applied than necessary, leading to significant wear, high replacement costs, and inefficient energy usage. A smarter solution is offered by nitrogen systems—particularly in the form of high-volume tank plate systems. These not only improve quality and reproducibility but also reduce maintenance efforts and enhance energy efficiency throughout the manufacturing process.

Physics Makes the Difference

The key metric is the modulus of elasticity. While steel reacts very rigidly with 210,000 N/mm² and hydraulic oil with 2,100 N/mm², nitrogen (at 150 bar) has a comparatively low value of 21 N/mm². This lower value acts as a damping element in the press shop: impacts and shocks, which often cause wear to punches or molds in hydraulic systems, are significantly cushioned. The result is a tool-friendly, elastic manufacturing process that enables longer service life while more precisely controlling process forces.

Three Ways to Efficiency

Steinel offers nitrogen solutions in three main designs:

• Gas springs—standardized standard parts, installed independently in punching and forming tools
• Composite systems—standardized components in hose or plate composites, suitable for higher cycle rates
• Tank plate systems—individually designed units with maximum integration and controllability

Tank plates are particularly the preferred solution for high-performance applications with high density, rapid cycle rates, or extreme demands on precision and service life. Designed as a customer- and tool-specific system, they can be optimally adapted to the respective application—including use as press-independent die cushions or as spring assemblies for modular tool construction. This supports a stable and repeatable forming process with a flat force curve—even under variable manufacturing conditions.

What Makes Tank Plate Systems Special

Tank plates impress with technical features that make them ideal for demanding applications:

• Designed for up to 150 bar filling pressure (standard on the market: 110 bar)
• Service life >10 million strokes, low maintenance
• Press control communicates with pressure switch
• Central pressure monitoring, control fittings with integrated burst protection,
• optional pressure switch
• Pressures can be adjusted during production
• Uniform pressure distribution across all cylinders
• System pressure increase limited to 20 percent, resulting in a constant force curve
• Low temperature rise
• Can be retrofitted in existing systems

Through additional volume drillings or external reservoirs, the overall system can be further optimized—for an even flatter force curve and increased process reliability.

Practical Example: Tank Plate Instead of Spring Pack

A specific application case with a customer in disc spring production clearly demonstrates the difference: originally, a modular tool was equipped with conventional system spring assemblies. Despite high-quality components, significant wear occurred rapidly during the production process—even leading to broken punches and fractured dies. After converting to a dual-circuit tank plate with 8 and 22 cylinders, the service life was tripled—while achieving a predictable maintenance schedule and reduced spare part requirements. Additionally, the required force could be set precisely and reproducibly—a decisive advantage in series production.

Hot Press Hardening and Deep Drawing? No Problem!

The application possibilities of tank plate systems go far beyond classic stamping and bending processes. In hot press hardening, networked systems enable automatic height adjustment as well as cross-level utilization—ideal for demanding forming processes with complex tool geometries. Tank plates have also proven effective in deep drawing: uniform pressure distribution through compound bores, individually adjustable circuits, and a flat pressure curve enable precise and material-friendly forming.

*Project sales, Steinel Standard Parts

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