Competitive advantage for sheet metalworking
Baumüller creates process advantages with technology solutions and drive technology
At Euroblech in Hanover, Baumüller will demonstrate how metal forming machine manufacturers and users can reduce their production costs and increase energy efficiency. Using three applications as examples, concrete approaches will be presented on how industry and automation expertise can be combined to give machines a competitive advantage. You can find Baumüller at the trade fair from October 22 to 25, 2024, in Hall 27 at Stand C155.
Application know-how in metal forming
As an experienced drive and automation solutions provider, Baumüller supports customers from planning to commissioning. Baumüller offers automation and drive systems for various types of presses such as servo-hydraulic presses, servo press brakes and servo eccentric presses.
Powerful drive solutions for more power and energy efficiency
Powerful drive components are used primarily in metal forming. At Euroblech, Baumüller will exhibit a drive system consisting of a b maXX 6500 servo converter and a high-torque motor from the DST series. This combination is particularly suitable for press applications with high requirements for the nominal torque at high peak torques.
Our DST-series high-torque motors achieve very high maximum torques, in order to provide the necessary power for the pressing process. The motors can be perfectly adapted to the press’s requirements thanks to different shaft and flange options.
The new mono devices in the b maXX 6500 family are even more compact thanks to their high power density. This allows for even smaller and, accordingly, fewer control cabinets. For example, if two servo drives in size 7 were required for a press application, two devices in the smaller size 6 can be used due to the higher performance of the new b maXX 6500 converter generation.
Smart Condition Monitoring: Mechanical monitoring for sheet metalworking machines
Condition monitoring solutions allow operators to keep track of the condition of many machines on a regular basis. This enables early detection of wear on mechanical components such as the electric motor, transmission, or hydraulic pump and the avoidance of possible unplanned machine downtime. The Smart Condition Monitoring software solution allows machine manufacturers to offer their clients condition monitoring without external sensors. The software is directly integrated in the servo-controller using the b maXX softdrivePLC, making it easy to retrofit and update. As an example, damage characteristics of the data to be analyzed will be displayed on a monitor on a survey dashboard at the trade fair.
Servo-hydraulics: Energy-saving pressure and volume flow control
A second exhibit will show a servo-hydraulic drive that offers a flexible solution for controlling a press's pressure and volumetric flow. Baumüller's servo pump combines the advantages of hydraulic power transmission with the benefits of electric servo drive technology. Servo pump drives for the hydraulic supply consist of a fixed displacement pump driven by a servo motor. The flow rate and pressure can be controlled precisely by highly dynamic changing of the motor speed. If neither flow rate nor pressure are required, the motor stops and does not consume any energy. The servo pump data will be transmitted live on a monitor at the exhibit.
Drive simulation: Faster engineering, better performance
With the ProSimulation simulation tool, Baumüller offers, among other things, ready-made simulation models of its drive components for servo presses. This means that drive components can be designed, tested, and optimized in the virtual environment. For the design of a servo-eccentric press, for example, a template was developed to simulate the servo press. The resulting digital twin offers many advantages, especially during the engineering phase: The development time is shortened, and the machine can therefore be placed on the market as quickly as possible and functionally reliable.
The simulation model, shown here using a servo-eccentric press as an example, enables an efficient drive design with minimal mains connection power and virtual commissioning.
Another use case for ProSimulation is the optimal design of energy management and the associated reduction of power peaks. Electrically operated servo-eccentric presses require very high peak power for short periods during the pressing process. Indirect stores can be used to reduce this power peak in the electricity system. The challenge now lies in optimally dimensioning the storage system. The peak power can be actively limited with the help of a design model. In this way, the optimum size of the DC link storage is determined in a cost-benefit analysis.
Servo-eccentric presses require a very high peak power for the forming process (red curve). By using external intermediate circuit capacities, the maximum peak power in this example can be significantly limited to approx. 600 kW (green curve).
Machine template: Simple peripheral connection through a virtual master axis
Baumüller offers a complete system for servo-eccentric presses consisting of engineering, hardware, and software. The Motion-Axis servo press software template has now been extended on the basis of the b maXX PLC mc control platform. The InchMode and JogMode functions make commissioning easier for the user, e.g. after a material or tool change. .
Another new feature with extensive benefits is the virtual master axis. The MasterEngineForming function is integrated into the control system and acts as a comprehensive clock generator for the entire press line. With the help of these functions, the external participants can synchronize their process steps with the pressing process. In addition to a simpler connection, this also means fewer interfaces on the customer side.
Fewer interfaces, simpler connection: The MasterEngineForming function serves as a virtual master axis on which the entire periphery can be synchronized.
Reach your goal in just a few steps: Optimized process controlling through improved visualization
The process in full view: The new HTML5-based visualization with a fixed sidebar and header bar provides an improved process overview.
Machines and systems continuously generate data that must be collected and evaluated to ensure efficient production. The new machine visualization for servo presses supports this with open interfaces, the latest HTML5 technology, and easy operator handling. Another advantage: Web-enabled end devices such as tablets or smartphones are supported for remote access. Communication with the control system is possible via the standardized OPC UA interface. This future-proof machine visualization is, therefore, also suitable for IoT-applications.
Baumüller Group
Euroblech, October 22–25, 2024
Hall 27, Stand C155 – Hanover
