A Servo Electric Press is a system that uses a linear actuator controlled by an AC or DC servo motor to deliver linear motion, similar to a press cylinder. Servo presses utilize ball or roller screws to offer precise control over speed, position, and force. Though a servo press isn&#;t necessary for all applications, it can be ideal for some. In this blog post, we&#;ll take a look at a few advantages and disadvantages of a servo press, and when this type of press might be the best choice for your application.
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What is a Servo Press?
A servo motor is typically an AC brushless electric motor that uses either an open-loop or closed-loop motion control system. Open-loop control systems do not incorporate any feedback in operation &#; these systems simply follow directions from the controller without reading output or sending data back to modify input.
Conversely, a closed-loop system, that&#;s more commonly used today, is controlled by motor feedback signals that make it possible to make micro adjustments to positioning, speed, and torque automatically as needed. As commands are being sent to the motor, a sensing device called an encoder sends positional, speed, and directional data back to the control system based on output. Torque feedback is also sent back to the control system which helps measure the force exerted by the linear actuator. This allows a servo press to be able to work with great precision, accuracy and control. Servo presses have many advantages as an option for industrial production.
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Advantages of a Servo Electric Press
High Accuracy
The positional feedback system within the servo motor press creates a highly accurate operation. The system has the ability to make very fine adjustments to meet the needs of the process. This is ideal for jobs with tight tolerances, or those working with very expensive materials.
Repeatability
Servo presses not only operate with a high level of accuracy, but their operation is steady and repeatable. Even as loads on the motor change, the controls can adjust accordingly to achieve the desired results. If the demands on the press frequently change, a servo electric motor is optimally designed to meet these needs.
Exceptional Control
The closed loop control system allows the press to operate with a very high degree of control. Though these presses can operate quickly, and with great power, they can also be carefully and precisely adjusted. The actuator&#;s positional feedback provides an incredible degree of control to the speed and position of the actuator.
High Powered
Even operating with high accuracy and control, the servo electric press does not sacrifice power. These types of presses can work with delicate materials and highly precise processes as well as very tough materials requiring a great deal of force.
Quiet
Many high-powered motors are also very loud which require your operators to have hearing protection when in their proximity. A servo motor press is electrically powered, and produces very minimal noise only during the press cycle.
Fast
A servo motor press can work very quickly, up to speeds of around 300mm/s. The feedback loop system allows the motor to adjust itself as needed, without interfering with the pressing process. When it&#;s important to produce components or complete jobs quickly and with great efficiency, a servo motor press may be ideal.
Disadvantages of Servo Motor Presses
Though servo motor presses have many advantages, there are also some disadvantages. It&#;s important to balance these factors to find the right press for your needs.
High Cost
As previously discussed, the servo motor operates smoothly, accurately, quickly, and can produce a great deal of power. However, this optimal performance comes at a cost. Servo electric presses tend to come with higher initial costs to most other types of presses, including full hydraulic options.
Complex
Servo motors are more expensive generally because they use more complex construction and components. This also means they have more expensive parts and are difficult to maintain. While most presses have a range of issues that can be addressed with in-house maintenance, servo press components will most likely need to be sent back to the factory for repair. Extra components, emergency maintenance and off-site maintenance can be costly and time-consuming.
High Voltage
The high power output offered by servo machinery also comes with high power supply. Most servo press machinery requires either 480 or 240V of electricity, which increases potential safety risks for an operation compared to low or no voltage options like pneumatic presses.
Specific Applications
Servo presses can perform a range of applications and can offer advantages for jobs with very tight tolerances, where precision and accuracy are an extremely high priority such as in medical device or aerospace manufacturing. Servo actuators are used outside of assembly to control the function of many products, like robots, drones and other electronics. With such precise operation from a closed-loop feedback system, servo actuators are even used to control the function of several vehicles in operation, like controlling steering motion or the speed of aircraft, submarines and automobiles.
If this level of precision and functionality isn&#;t essential for your applications, you may be needlessly overspending. It&#;s helpful to have details about your applications to choose a press, including the materials you&#;re working with, the dimensions of the workpiece, and the type of operation you&#;re conducting. This will help you get the right amount of force for your press, and get the right type of press.
Is a Servo Press Right For You?
There are many different types of presses to choose from for your application. Finding the right design and configuration requires some careful consideration and planning. If your process requires a great deal of accuracy, precision, and smooth operation, a servo press might be ideal for you. However, many of these complex processes can also be performed with a force and distance monitoring air over oil press for a fraction of the cost and there may be a range of pneumatic, hydropneumatic and even hydraulic options that could provide the capabilities you need with a higher return on investment.
If you&#;re looking for a high-quality factory press and you&#;re not sure about the optimal construction, contact us. Our press experts can help you find a press that is highly functional as well as cost-effective and quote either a servo press or alternative, designed to meet your needs.
Selecting the best press machine for your metal stamping operations is a very critical undertaking, which involves a great deal of understanding regarding the types of machines you choose to invest in. Some press types are better suited for certain production needs. In this article, we hope to give you a foundational understanding of the pros and cons of mechanical and servo presses, so you can be confident in choosing the proper press type for your next project or production expansion.
Mechanical Press Technology
The mechanical press machine has a long history in metal stamping seeing as how it was among the first kinematic mechanisms used in modern metal stamping. Mechanical presses are complex machines with multiple variations of the same machine type and have a wide range of applications and capabilities.
Overview - Mechanical Stamping Presses
A mechanical press machine is a type of press that can exert extreme amounts of force driven by mechanical means which involves a flywheel, crankshaft, and clutch-brake mechanism. Mechanical presses are fundamental machines in various metal forming operations due to their reliability, efficiency, and capability to produce a high volume of parts with consistent quality. One of the more common variations of a mechanical press is within the frame which we compare in another article here: C frame vs straight side presses.
Working Principle & Applications - Mechanical Presses
The fundamental working principle of a mechanical press involves the conversion of rotational energy into linear motion. This is accomplished by the flywheel storing rotational energy and releasing a controlled portion of said energy to drive the ram of the press. The ram then uses the force applied to shape the material based on the composition of the tool and die. This entire process is done with a great deal of speed and precision which is one of the many reasons why mechanical press machines are essential in high volume production environments.
Mechanical Presses are versatile machines and are suited for several common metal stamping applications such as:
Blanking
Coining
Drawing
Shearing
Embossing
Bending
Punching
Advantages - Mechanical Presses
Speed & Efficiency
Mechanical Stamping Presses excel in operating at higher speeds than servo press machines. This can be particularly advantageous for large-scale operations where every second of production matters. The continuous & rapid cycles of a mechanical press ensure a high output making them an ideal choice for repetitive high-volume production tasks.
Reliability & Durability
Mechanical Presses offer unmatched robustness & dependability. They are constructed with technology that has been proven and refined over decades. Their sturdy construction helps reduce unexpected breakdowns and maintenance leading to continual operation and minimized downtime.
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Power
These press models are known for the power that they can provide to a given operation. Mechanical presses can produce extreme amounts of force which makes them suitable for heavy-duty tasks and applications that use thicker more resistant materials, or processes with significant material deformation like deep drawing.
Cost Effectiveness
When looking at costs mechanical presses often have an advantage over servo press machines. Mechanical options typically require less upfront investment, which can benefit businesses operating with budget constraints. Another area where these presses have an edge is when considering maintenance costs. Costs associated with maintenance are often more straightforward and inexpensive leading to a lower total cost of ownership.
Limitations - Mechanical Presses
Flexibility
One of the primary limitations of mechanical presses is the reduced flexibility of the stroke length and profile. Unlike servo presses, which can adjust these parameters mechanical presses often have fixed stroke lengths and speeds.
Energy Consumption
Mechanical presses can be more energy-intensive. The flywheel, which is a key component in these machines, needs to continuously operate throughout the press cycle. This constant motion leads to a steady draw of power, which can result in higher energy consumption, especially in comparison to servo presses that use energy only when in motion.
Noise Levels
Noise is another factor to consider with mechanical presses. They tend to operate at higher noise levels due to the nature of their mechanical operations. This could require additional noise reduction measures in the workplace, such as sound enclosures or protective gear to ensure a safe work environment for operators.
One way to counteract the limitations of a mechanical press is by utilizing the adjustable stroke technology that we incorporate into our presses. When an adjustable stroke is paired with a variable frequency drive you can expect servo-like flexibility with the speed, consistency, and simplicity of a mechanical press.
Servo Press Technology
What makes a servo press stand out in terms of press technology is its incorporation of servo motors, which distinguishes it from traditional mechanical presses. These machines leverage the control of servo motors to drive the press ram mechanism, offering a high degree of accuracy and flexibility. Unique for their programmability, servo presses allow users to control the slide position, speed, and pressure with precision. Their adaptability makes them suitable for complex and varied stamping tasks.
Working Principle & Applications - Servo Presses
At the heart of a servo press is the servo motor, which directly controls the press&#;s ram movement. Unlike mechanical presses that operate on a fixed cycle determined by the flywheel, a servo press can adjust its stroke and speed in real time based on the task at hand. This is made possible by software that controls the servo motor, allowing adjustments to be made on the fly This results in a highly adaptable press, which can be tailored to specific production requirements.
Most of the applications that apply to a mechanical press can also be performed with a servo press.
Advantages - Servo Presses
Precision & Control
Some of the standout aspects of servo press technology lie in the amount of precision and control that it provides users. Unlike a mechanical press which operates on a fixed cycle, a servo press has a highly programmable stroke profile. This allows the user to adjust the motion, speed, and position of the slide at any point in the stroke. Servo presses can pause or slow down during certain points in the stroke to ensure proper time for feeds or transfer systems to complete their function. This makes very intricate or complex forming processes much more viable in applications where gradual or variable force is needed to guarantee sufficient part quality.
Energy Efficiency
Servo press machines contribute to energy-efficient manufacturing thanks to the press only consuming power during the stamping process whereas with a mechanical press energy consumption is constant when the machine is powered on. Another way servo presses contribute to energy efficiency is by optimizing the stroke profile for specific jobs.
Versatility
Thanks to the programmability of the stroke profile the servo press can offer a great deal of versatility for metal stamping operations. They can adapt to different materials, thicknesses, and forming requirements without the need for physical or manual adjustments to the press. The versatility of the servo press makes it a quality choice for operations that tend to see a high mix of parts that vary in requirements.
Reduced Set-Up Times
With the right controls that offer tool/program storage capabilities, these presses can recall and adjust to the different programs that have been stored with ease. This helps drastically reduce setup and changeover times for operators which can be a huge factor for high-mix, low-volume stamping operations.
Limitations - Servo Presses
Initial Investment
Due to the advanced controls, programmable features, and other components a servo-driven press comes at a much higher initial cost compared to traditional mechanical presses. This type of upfront capital requirement may serve as a barrier to entry for smaller operations, or those with limited budgets.
Maintenance
Since servo presses rely on sophisticated software and controls, this makes the maintenance of these machines more complex than that of their mechanical counterparts. The requirement of specialized knowledge for both the mechanical and software aspects necessitates a higher level of technical expertise. Operations may encounter increased maintenance costs from training their existing operators and personnel. These factors and the need for specialized diagnostics, updates, and system checks may lead to a higher total cost of ownership.
Operator Training
The complexity and programmability of these presses demand a higher level of operator training and understanding. Maintaining skilled personnel is essential to fully leveraging the capabilities, and maintaining efficiency. This can be challenging in times and areas where skilled labor is scarce or for companies that place less value on developing and educating their personnel.
Reduced Operating Speeds
Although servo presses offer unmatched control and programmability they operate at reduced speeds compared to mechanical presses. For operations that require high-speed stamping, a servo press may not serve as the best available option.
Comparing Mechanical and Servo Presse
s
Performance
Mechanical presses lead the pack in terms of raw speed and simplicity, making them more suitable for high-volume job requirements. Servo presses, however, offer much more programmability and flexibility making them a great option for applications that require control and adaptability.
Efficiency
Servo presses are often more energy-efficient, as they consume power on demand as opposed to running continuously. This efficiency can lead to cost savings in the long term.
Precision
Servo-driven presses when utilized properly can provide exceptional precision in operation thanks to the control and programmability. Mechanical presses serve as a consistent option and precision can be determined by the quality and condition of the press.
Flexibility
Typically servo presses offer more flexibility, but for the tradeoff of less operational speeds. This makes them an ideal candidate for high-mix, low-to-mid-volume operations. Traditional mechanical presses tend to lack the flexibility to run multiple jobs optimally. This is one of the reasons the adjustable stroke feature is standard on a Sangiacomo press, so you can tune the stroke of the press to the application at hand which ensures efficient production. Also as mentioned earlier when you pair an adjustable stroke press with a variable speed option you can obtain similar flexibility to that of a servo press without giving up operational speed.
Operational Implications
Whether you are a seasoned metal stamper or a beginner looking to bring part production in-house it is important to know what will be required of your business to run a stamping operation successfully. This includes having skilled operators and maintenance personnel that can run the press and keep it running optimally, also you must invest time and money into ensuring that operators who run the press have the knowledge and skill to do so properly. This can be quite a challenge for those who are new to stamping, and servo presses present unique challenges in terms of programming the profile of the stroke. With mechanical presses the operation can be significantly simpler, so keep that in mind when considering your options for purchasing a press. If you are not going to be committed to investing in the proper support and training required to run the press you can run into significant issues down the road.
The choice between mechanical and servo presses should be informed by the specific needs, operational requirements, and future objectives of your metal stamping operation. Mechanical presses, with their speed, reliability, and cost-effectiveness, are ideally suited for high-volume production tasks where the simplicity and robustness of the machine can translate into operational efficiency and reduced downtime. On the other hand, servo presses offer precision, control, and versatility, making them perfect for complex stamping applications.
The decision should also consider the long-term operational implications, including the availability of skilled labor, maintenance requirements, and the total cost of ownership. Mechanical presses are generally simpler to operate and maintain, while servo presses require a higher level of skill and technical knowledge due to their sophisticated control systems. Therefore, investing in proper training and support is crucial regardless of the technology chosen to ensure optimal performance and avoid potential operational issues.
Ultimately, the selection between a mechanical and servo press should align with your operational goals, technical capabilities, and the nature of the stamping tasks at hand. By carefully assessing these factors, manufacturers can choose the press technology that not only meets their current production needs but also positions them for future growth and adaptability in the evolving landscape of metal stamping.
Need Help Finding the Right Press For Your Operation?
If you or your business needs help finding the right press for your application give us a call or fill out a form, and a member of our team would be happy to pair you with the right metal stamping solutions.
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