When to Rebuild, Retrofit Or Replace a Hydraulic Press

When deciding whether to rebuild, retrofit or replace an old hydraulic press, there are many factors to take into account such as your budget and timeline constraints.

When a 40-year-old multi-action hydraulic forming press needed an updated automation system, speed was of the essence. ACT, KCC Software and SMG collaborated to meet their customer's tight deadline.

Typical Repairs

Hydraulic presses and C-frame presses are essential tools of many industries, such as printing, industrial manufacturing, automotive production and textile. When these machines malfunction or require repairs it can be an expensive and disruptive event that disrupts production schedules.

Repairing hydraulic presses necessitates an in-depth examination of all major components and an intense cleaning process to eliminate rust and dust particles. Doing this helps avoid future leaks or failures in the future.

Maintaining an optimal oil level and lubricated press are critical for optimal operation. If the oil becomes too hot, replacing it will reduce heat load on the system and maximize performance.

Maintaining proper fluid levels, filtering and fixing leaks inside the hydraulic system will reduce internal heat buildup that could accumulate inside. This heat is often responsible for slow operation and component malfunctions.

If the press's ram is not centering in the cylinder, it could be due to wear on platen gibs or other issues that require adjustment. Shimming these gibs can correct this issue, but the ram still needs to be checked and repositioned if necessary.

Rebuilds

Hydraulic press rebuilds typically involve replacing worn parts, repairing hydraulic valves and accumulators, and improving the system's overall functionality. These repairs can extend the life of a press while making it more productive and cost-effective.

Kiefer Tool maintains a variety of hydraulic and mechanical presses to ensure they run optimally. These machines contain many parts that can fail, such as ram seals, cylinders, and bushings.

In this instance, the automation system had to be revamped as well. The 175-ton hydraulic forming press had an outdated control panel.

KCC Software of Huntsville, AL designed an updated automation system for SMG Press that enhanced its performance. This enabled machine owners to monitor their equipment more effectively and identify potential issues before they became major issues. As a result, SMG's hydraulic forming machine remains operational and working at its maximum potential.

Retrofits

When a press is outdated, it's time to upgrade it with modern control technology. This can enhance production, boost efficiency and make it safer to operate.

Hydraulic machines in particular are ideal candidates for an upgrade in control system that could save the owner up to 50% over purchasing a new machine. Furthermore, it will give them a superior product to offer their customers.

Another advantage of a hydraulic press retrofit is energy efficiency. Aging pumps, motors and hydraulic fluids tend to consume more electricity than necessary due to inadequate design choices.

A hydraulic press retrofit with an optimized control system that makes use of controllers, variable-speed pump drives and motors can significantly reduce power consumption while still maintaining accurate control and optimal cycle performance. This could result in lower production costs per part as well as increased profitability for the stamp shop.

Replacements

Hydraulic presses are an automated levering and lifting system commonly employed in construction sites. Not only do they work with most materials, but they're also easy to troubleshoot and maintain.

They are cost-effective to purchase and install, with parts readily accessible worldwide. Furthermore, their maintenance requirements are minimal.

Hydraulic presses are not only user-friendly and cost-effective, but they're also safe. Built-in overload protection safeguards both the operator and press machine tools from damage during usage.

These presses are remarkably quiet, thanks to the absence of flying wheels and moving parts. Additionally, they tend to last longer than mechanical presses because tool parts aren't subjected to intense vibration, shock or impact.

High fluid temperature can be caused by anything that increases the heat load or reduces its capacity to dissipate heat, such as an excessive workload, failed components with internal leakage and/or faulty pressure relief valves. To avoid these problems, clean the reservoir and ensure there's enough flow through any heat exchanger if equipped.