Fast, powerful and easy on the die

    Schuler unveils new 16,000-kN drop forging press with ServoDirect Technology at its Erfurt plant

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    Shorter pressure dwell times and an increased output of 35 strokes per minute – and all in continuous operation. These are just some of the benefits offered by the 16,000-kN-strong drop forging press with ServoDirect Technology recently unveiled by Schuler. Built for a customer in the automotive industry, the innovative line now introduces freely- programmable slide motion to the world of forging.

    “The pressure dwell time can be reduced to a minimum while also optimizing the time for spraying and transporting,” explains Jochen Früh, Managing Director of Schuler Pressen and Head of the Technology Field Forging. “That means that output in high-speed mode can be increased to 40 pieces per minute, while die service life can be prolonged by 15 to 20 percent due to reduced heat input.”

    Instead of a drive running continuously at the same speed, servo forging presses feature one or more torque motors, which are either flanged to the driveshaft directly or via a planetary gearbox. The PK 1600 SDT model that Schuler unveiled in Erfurt boasts two Oswald torque motors, each with a rated capacity of 377 kilowatts; these are highly-dynamic drives that act directly on the crankshaft. Due to the elimination of the flywheel, clutch, brake and drivebelt, the amount of mechanical and electrical loss has also been reduced. “This makes overall energy consumption more favorable and reduces the amount of maintenance and servicing required,” states Jochen Früh.

    Intermediate storing reduces energy needs

    The intermediate storing of energy in an external flywheel storage device reduces energy consumption, and also the load on the factory network caused by energy peaks. The electrical energy created by the regenerative braking of the drive motors is transformed into mechanical rotation energy. This is then returned to the servo drives as electrical energy during the brief peak energy needs of the drive motors – such as during heavy acceleration of the slide’s downward motion and the forming process.

    For this and other reasons, ServoDirect Technology is ideally suited to tryout operation: The variable slide speeds enable slow and sensitive running of the press and transfer system. This means that dies can be put into operation more swiftly and securely.


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