Disadvantages of Hydraulic Press Automation Systems

Hydraulic press automation systems are an invaluable asset to stamping manufacturers. They make it simpler and faster to produce parts with higher quality and consistency than with traditional mechanical presses.

However, they also come with their drawbacks. These include safety risks, maintenance needs, cost concerns and efficiency problems.

Safety Issues

Hydraulic presses are essential tools in industrial production. Not only do they exert incredible crushing force on many processes, but they can also present serious safety hazards if not used properly.

One of the most hazardous types of hydraulic press injury is injection injury. This occurs when fluid from a press leaks out, striking people and other equipment pieces.

Another potential risk is hydraulic ram failure, which could cause an unexpected release of force. This could cause severe cuts and other injuries in the area of impact.

All employees who work near a hydraulic press should receive adequate training on how to safely and correctly operate the machines. This includes learning how to identify potential issues before they lead to an accident.

Maintenance Issues

Maintenance of hydraulic presses is essential for avoiding machine breakdown and keeping downtime to a minimum. These systems are designed to function under extreme pressure and temperatures, so parts and fluid replacement should be done regularly to avoid breakdown or malfunctioning.

Preventative maintenance can save your business money in the long run by avoiding machine downtime and maintaining productivity levels. Furthermore, these practices guarantee your system is operating optimally so you get maximum value out of your investment.

Verify the oil level and temperature - Press systems should operate at approximately 120 degrees F. If the oil gets too hot, it could reduce the life of your press's components.

Other essential checks should include the reservoir fluid level (if equipped) and airflow around the reservoir. If either are low or contaminated, they may need to be refilled or replaced. Furthermore, an obstruction in airflow within the reservoir could cause heat dissipation issues.

Cost Issues

Hydraulic press automation systems can be costly, which is one of the main reasons why many companies opt for pneumatic systems instead.

Though hydraulic presses may be more expensive, they also come with several advantages. These include high energy efficiency and low maintenance costs.

Additionally, these systems are remarkably dependable. When used properly, they will last for years with minimal upkeep required.

However, they come with their drawbacks as well. These could include costs, safety or efficiency issues.

Furthermore, these disadvantages can be expensive to repair or replace should something go awry.

In 2012, Southern Manufacturing Group (SMG) required to rebuild their 175-ton hydraulic forming press and associated control system. This would have been an expensive endeavor.

Instead, SMG decided to invest in an upgrade that would enable them to boost production rates and enhance quality. To do so, it reautomated its press with new recipes and automated quality data tracking systems.

Efficiency Issues

Hydraulic presses are essential tools in many industries, yet they also pose a significant injury risk to operators. That is why these machines must be designed and constructed with safety in mind.

Efficiency issues associated with hydraulic press automation systems can be addressed by adding variable-frequency drives (VFDs). These drives draw energy on demand during stamping operations, leading to energy cost savings for the business.

Presses can also be retrofitted with pneumatic dwell circuits to reduce energy consumption by monitoring and adjusting pressure using a pneumatic pump.

Alpha Lehigh in Alpha, NJ has recently upgraded their Hydraulic Press Division's powder metal presses with a PLC-based control system from Concept Systems Inc. The upgraded system enables press parameter tuning for each product recipe while collecting process data that is fed into other systems for statistical process control.