Retrofitting mechanical flywheel presses into servo presses
Modernization instead of replacement
Flywheels as energy storage systems have a long tradition in forming technology. Driven by an asynchronous motor and using clutch-brake combinations, the use of such a kinetic energy storage system is widespread and time-tested. However, this system does not allow for any variation in forming speed, meaning that the flexibility of motion profiles — which is required or advantageous for many forming processes — is technically not feasible.
To take advantage of greater flexibility in the forming process, you don't necessarily have to buy a new press. If the mechanical components of your press are still in good condition, you can upgrade your machine by retrofitting the drive system and control unit to current standards. This typically comes at significantly lower costs—and often faster turnaround—than purchasing a new machine.
By retrofitting the drive system, a flywheel press (left) is transformed into a servo press
High-performance high-torque motor instead of standard asynchronous motor
A mechanical flywheel press can generally be converted into a servo eccentric press with minimal design modifications. After dismantling the old drive system and conducting a quality inspection of the mechanical components, integrating the DST2 high-torque motors with the existing gearbox is usually straightforward. By using b maXX servo drives and the comprehensive control package, flexible and dynamic operation of the press is now possible.
Our DST2-series high-torque motors achieve very high maximum torques, in order to provide the necessary power for the forming process. The motors can be perfectly adapted to the press’s requirements thanks to different shaft and flange options. We also enable the press power to be divided between multiple motors connected via a master-slave coupling.
Since numerous wear parts such as the clutch, brakes, and V-belts are also eliminated, the modernized machine requires significantly less maintenance.
Capacitor instead of flywheel: Multifunctional energy storage
While a flywheel serves as the energy storage system in a mechanical press, in a servo press, this function is taken over by the DC link capacitors. Through intelligent energy management, the connected load to the power grid can be kept as low as possible, saving both energy and costs. In addition, the b maXX grid inverters enable energy to be fed back into the power supply network.
Fewer wear parts, more flexibility: When a conventional flywheel press is retrofitted into a servo eccentric press, the number of wear parts is reduced, and the motion profile can be adapted much more flexibly
Compared with conventional mechanical presses, servo eccentric presses provide considerable advantages, such as increased productivity and higher product quality. Furthermore, they offer the user enormous additional flexibility.
Your advantages
- Increased productivity
- Higher product quality
- Flexible motion profile
- Full press force even at low speeds
- Reduced maintenance
Boost your competitiveness through greater efficiency and flexibility in your press. Take advantage of our application expertise in metal forming.
Precise-fitting and customized: From the electric motor to the complete drive system
Baumüller offers the exact service you require - from individual motors and components to comprehensive drive systems with control technology. We always support your precise needs. Baumüller is a partner for machine manufacturers and a supplier of complete systems.
from the motor to the overall system
< 100 t – 3000 t
Eccentric presses
for system optimization
Whether refurbishment or modernization – Baumüller provides the perfect drive solution for your servo eccentric press.
Converting a traditional mechanical press into a servo press
Standard control cabinets through to completely wired special control cabinet
For many years, we have been implementing custom solutions for renowned machine and plant manufacturers - from the standard control cabinet through to the completely wired special control cabinet. You receive everything from us, a single source that can therefore deal optimally with your needs and wishes:
Planning – design – sheet metal production – serial production - assembly - installation
Your path to a qualified quote
You would like a no-obligation consultation or quote? Then contact our experts.
We discuss the relevant technical details with you and together we define the requirements. Only then do we undertake the qualified design of the complete drive system. After checking the specifications, you receive a qualified quote from us.
Baumüller is your partner for the production-ready design and optimization of your drive system. As a non-group-affiliated, mid-sized company, we are able to respond to the wishes of your customers quickly and efficiently with innovative drive solutions. This makes us the perfect partner for challenging projects and future technologies.
Write us a message, our sales experts will be happy to advise you.
