How to Improve Hydraulic Press Automation System Efficiency

When designing a hydraulic press automation system, the components used and how software controls are applied all have an effect on efficiency.

One of the most efficient energy-saving techniques for hydraulic presses is to utilize a system that permits pump unloading during cycles or employ load sensing control.

1. Optimal Design

Efficiency is a paramount goal for most manufacturers looking to enhance their equipment. Hydraulics is one area where manufacturers can see dramatic improvements in machine effectiveness.

Optimizing hydraulic press automation system efficiency is one of the most efficient methods to boost production output. It uses a set of standards or criteria that guarantee development remains focused on important elements and does not veer off track.

Additionally, it helps developers reduce any prejudice they may develop towards a particular design model. Furthermore, it offers an avenue to avoid investing time and resources on ideas which ultimately prove ineffective or useless.

Optimizing design can be especially useful when conducting experiments that have multiple objectives and different parameters of interest. It provides a framework for balancing the needs of each study, which is especially critical when dealing with implementation studies involving various treatment combinations or disallowed combinations.

2. Choosing the Right Components

When it comes to hydraulic press automation systems, the right components can have a major influence on their efficiency. These include valves, cylinders, motors and pumps.

Tim Wilson, design engineer at Greenerd Press & Machine Co. in Nashua, N.H., suggests that manufacturers who are thinking about retrofitting or upgrading their hydraulic presses should first consult with a hydraulic press expert for an onsite evaluation.

Manufacturers can utilize this knowledge to identify cost-effective opportunities to upgrade and improve their equipment. According to Henning, these improvements can enhance quality and production while decreasing overhead expenses and avoiding expensive downtime.

Another critical consideration is process requirements, such as target force accuracy or overshoot. Basic hydraulic systems offer repeatability of +-0.020 to 0.030 inch; however, certain applications may require tighter tolerances.

3. Controlling the Process

When manufacturers look into improving hydraulic press automation systems, they often focus on components like motors, pumps and valves. These can be retrofitted or upgraded with new additives that boost efficiency and boost output.

Pump and motor seals have also evolved over time, leading to less leaks, reduced maintenance expenses and enhanced productivity.

KCC Software was approached by a manufacturer who needed an automated system for their new hydraulic press, at an affordable cost. They wanted the system to reduce cycle times and enhance production consistency.

KCC Software selected a Do-more series PLC (Cumming, GA) that provides programs and tasks essential for an efficient automation system controller program. This allowed them to divide code into manageable pieces that could be reused multiple times within one program or used as starting material when developing new programs. This feature proved crucial in SMG's hydraulic press automation project.

4. Optimizing Maintenance

A well-designed hydraulic press automation system can increase productivity and decrease maintenance expenses. This means you'll experience less downtime, allowing you to maximize the value of your machine investment.

One of the primary causes for downtime is a leaky hydraulic system. If this issue is caught early enough, it can be remedied quickly and save costly repairs in the future.

To keep their processes running efficiently, manufacturers are increasingly turning to safety components like a safety curtain that can warn operators when they get too close to the press. Furthermore, installing an infrared sensor can detect if someone is in an area where they could get injured.

Another way to enhance hydraulic press efficiency is by decreasing the strain placed on motor pumps. This can be accomplished through the use of a prefill system and buffer system.