This article, focusing on keywords related to servo, bending, press brake, hydraulics, hydraulic oil, slider, speed, drive, precision, and power consumption, discusses the advantages of pure electric servo press brakes compared to hydraulic press brakes. It is intended for informational and educational purposes only.
In recent years, the maturity and cost reduction of high-power, high-torque servo motors and drive technologies have driven the increasing application of related electric servo drive devices. Presse piegatrici CNC, widely used in the sheet metal industry, have ushered in a new trend of replacing hydraulic main drives with electric servo main drives. The tonnage and output of electric servo CNC press brakes are both increasing. This article elaborates on the advantages of pure electric servo press brakes compared to hydraulic servo press brakes in terms of energy saving, environmental protection, processing efficiency, bending precision, and maintenance costs.
1. Energy Saving
One advantage of pure electric servo drive technology is that the input power of the motor is proportional to the load power. It consumes a large amount of power during bending, a small amount of power when the slider is unloaded and moving upwards, and virtually no power when the slider is stopped. In contrast, the main motor and hydraulic pump of a hydraulic servo press brake continue to operate even when the slider is not working, consuming electrical energy. Furthermore, the main drive efficiency of a pure electric servo press brake is above 95%, while the hydraulic transmission efficiency of a hydraulic servo press brake is below 80%, and the efficiency decreases further after the hydraulic system components age and wear.
Taking a 100t press brake as an example, the main power consumption of a pure electric servo press brake is approximately 12 kWh/d, while the hydraulic system power consumption of a hydraulic press brake is approximately 60 kW·h/d. The pure electric servo press brake saves approximately 80% in energy.
2. Environmentally Friendly And Pollution-Free
Electric servo press brakes do not use hydraulic oil, eliminating the hassle of changing hydraulic oil or disassembling hydraulic components. Therefore, there is no hydraulic oil leakage during replacement, disassembly, or daily operation, and no waste oil disposal or pollution.
3. High Slider Speed And High Production Efficiency
The response speed of the servo motor is faster than that of the hydraulic servo motor. Taking the 100t pure electric servo press brake developed by Kaifeng CNC Company as an example, the return and rapid descent speed of the slide reaches up to 200mm/s, and the working speed is 0~20mm/s. Most hydraulic press brakes of the same tonnage have a return and rapid descent speed of less than 120mm/s, and a working speed of 10mm/s. Hydraulic servo press brakes are affected by the environment and the heat generated by the hydraulic system, requiring preheating or shutdown for heat dissipation. Once a hydraulic system malfunctions, troubleshooting requires high technical skills and is time-consuming. Pure electric servo press brakes have fewer components and a very low failure rate, so these problems are nonexistent. Therefore, the processing efficiency of pure electric servo press brakes is nearly twice that of hydraulic press brakes of the same tonnage.
4. High Bending Accuracy
The bending speed of the electric servo press brake is adjustable, allowing bending according to different thicknesses, materials, and bending lengths. A more suitable bending speed can be set to improve bending accuracy and maintain high productivity. The deflection compensation shaft of the electric servo press brake adopts a VILA structure compensation device, resulting in even higher bending accuracy.
Hydraulic press brakes have a bending angle error within 1°, while servo press brakes are driven by servo motors, resulting in higher transmission accuracy. By measuring the bending angles of various sheet metal specifications, the bending angle error can be well guaranteed to be within 0.5°.
5. Low Maintenance And Operating Costs
Hydraulic press brakes require regular hydraulic oil changes; pumps, valves, and seals are prone to failure and damage, and the hydraulic system is easily contaminated, making troubleshooting difficult. Once contaminated, the hydraulic system is difficult to clean, causing environmental pollution. Pure electric servo press brakes have a simple transmission system, low maintenance costs, and only require regular lubrication.
The design and manufacture of electric servo press brakes aim for high bending accuracy, high operating efficiency, and high reliability. Finite element analysis was performed on the bed and slide, and the rigidity of the bed and slide was optimized and strengthened. Based on the analysis of pure electric servo press brakes and hydraulic servo press brakes in terms of energy consumption, environmental protection, processing efficiency, processing accuracy, and cost.
