Greater efficiency and power for metal forming
Baumüller’s intelligent drive architecture for maximum efficiency in the synchropress® 4M servo screw press from synchropress
synchropress GmbH’s custom-built servo screw presses are used in a wide range of applications, from manufacturing the smallest metal parts to producing batteries and fuel cells. The East Westphalian manufacturer meets these diverse requirements with a modular design concept. synchropress builds each press to the customer’s specifications for pressing force, dimensions and travel speeds. A fully assembled synchropress® servo screw press can be used in a variety of applications. It can serve as a dedicated tryout press for tool testing or as a production press in three-shift operation.
The integrated design of the motors ensures that the synchropress® 4M is significantly more compact and requires less floor space | Image: synchropress
To continue giving its customers a clear competitive edge, synchropress faced the challenge of building on the strengths of its screw presses. “The machines needed to control the forming process precisely and deliver maximum forming force while keeping energy consumption as low as possible,” says Alfons Knust, sales representative at Baumüller, describing synchropress’s requirements. To meet these requirements, screw press manufacturer synchropress and drive system manufacturer Baumüller jointly developed an intelligent drive system. This drive system is now used in all synchropress presses with pressing forces ranging from 100 to 10,000 kN.
Compact and highly synchronous for precision parts
The synchropress® drive system consists of four threaded spindles, which are driven by highly dynamic DSD2 servo motors or powerful DST2 high-torque motors, depending on the required pressing force. The motors are mounted axially in the press table, in line with the spindle mounts. The integrated design of the motors ensures that the press is significantly more compact and requires less floor space.
The b maXX 5100 active mains rectifier units and b maXX 5500 axis units provide highly synchronous motor control, ensuring the precision and repeatability required for the forming process.
A system solution for precision and power: The drive system of the synchropress® 4M-10000 consists of DST2 high-torque motors and b maXX servo converters from Baumüller | Image: synchropress
How does the DC link connection reduce the screw press’s energy consumption?
At the heart of the system is a common DC link. It connects the b maXX 5100 active mains rectifier unit to the b maXX 5300 axis units or – for applications requiring higher motor power – to the high-performance b maXX 5500 units. It allows larger amounts of energy to be stored in the DC link capacitors. This buffers process-related power peaks, allowing the electrical connection to be sized for a significantly lower load. This reduces the connected load and the associated costs.
How does the press use braking energy during forming?
The DC link connection also recovers braking energy from the forming process. The movement of a synchropress® ram not only draws energy but also generates braking energy during deceleration after the forming stroke The DC link makes it possible to buffer – that is, temporarily store – the energy generated during each stroke and make it available for the next stroke. This reduces the press’s actual energy consumption.
How does the active mains rectifier unit increase the available motor power?
The b maXX active mains rectifier unit feeds excess energy from the common DC link back into the power supply. In addition, it increases the drive system’s motor power: It raises the DC link voltage from 400 to 760 volts, thereby shifting the motor characteristic curve upward. This expands the available speed range.
Smart drive solution for the synchropress® 4M: The b maXX active mains rectifier unit increases the DC link voltage (1), thereby expanding the motor’s speed range (2), and feeds excess energy back into the power supply (3). This requires a common DC link
How is the drive for the synchropress® 4M properly sized?
To size the drive system for the synchropress® 4M, synchropress uses Baumüller’s ProSimulation tool. Creating a simulation model allows the machine’s behavior to be tested virtually in advance. This helps avoid oversizing the drive and ensures that the press’s connected load is optimally matched to the specific application.
The simulation model of the screw press in ProSimulation enables efficient drive sizing and minimizes the machine’s connected load
Baumüller x synchropress: Driving innovation together
Baumüller and synchropress have worked together for many years in a partnership built on trust. The process partnership benefits both companies. It allows them to openly share their respective product expertise to find the optimal system solution – ideal conditions for innovations built for the future.
For many years, Baumüller has been a reliable supplier and valued partner for us. Our continuous exchange and mutual trust enable us to develop solutions that steadily enhance our machines and offer our customers real added value.”
Johannes Hülshorst, Managing Partner at synchropress GmbH
