Take the pressure off, boost efficiency – the easy way to servo hydraulics
Hürsan Pres opted for an efficient drive system from Baumüller for its new press
The specifications provided by Hürsan Pres were clearly defined. The new SERVO press was to be designed to meet the growing demand for higher precision and lower energy consumption. The drive system should be more innovative, but everything else, including the machine control system, should remain with the existing suppliers. The press manufacturer was seeking a new drive solution and a partner with a powerful servo drive system and expertise in metal forming applications. The result is a new system from Baumüller, featuring high press force combined with high energy efficiency and precise pressure and flow control, all embedded in proven technology.
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The SERVO series was launched at the end of 2024 and is the first press from Hürsan Pres with a servo-hydraulic drive system
"Baumüller met all our requirements, and we were really very satisfied with the cooperation", said Mehmet Sarı, Export Sales Manager at Hürsan Pres, when the new SERVO servo-hydraulic press was launched in October 2024.
The Turkish manufacturer Hürsan Pres is a leading supplier of hydraulic presses. The company was founded in 1976 and has been achieving high quality and customer satisfaction ever since. Hürsan Pres maintains its leading position in the industry with innovative engineering solutions and experience. The CE-certified machines are manufactured in Turkey and exported to more than 45 countries around the world.
Hürsan Pres opted for an efficient drive system from Baumüller for its new press. The servo-hydraulic solution for the 400-tonne machine consists of the dynamic DSD2 servo motor series, the b maXX 5500 servo drive, and the servo-hydraulic software module integrated in the servo drive.
Servo hydraulics: Energy-saving pressure and flow rate control
The new SERVO from Hürsan Pres combines all the advantages of hydraulic presses, such as high pressing forces and flexibility, and, thanks to the powerful motor-pump combinations from Baumüller, also offers optimization of cycle time, repeat accuracy, energy consumption, and environmental compatibility.
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. Since the drive only generates output when the servo pump is actually used, the machine consumes far less energy. The energy-saving potential of Baumüller's servo hydraulics is therefore particularly evident during process pauses.
The high energy efficiency of the servo-hydraulic solution is achieved through demand-based pump output. When the press is at a standstill, e.g., during the dwell time, the motors are also at rest and consume no energy
The servo motors of the DSD2 series feature an excellent torque-inertia ratio. This ensures maximum dynamics, i.e., fast and precise production
Powerful drive solutions for more power and energy efficiency
Baumüller's DSD2 servo motors are used in the SERVO press. The series offers very low moments of inertia to provide the necessary dynamics for precise pressure control during the forming process. The hydraulic pumps can be attached directly to the servo motors, thanks to the different shaft and flange options. The elimination of the coupling and pump bracket reduces the overall length, operating noise, and installation time. In addition to this, the pressing power can be distributed across several motors connected via a master-slave coupling.
Servo hydraulics independent of the machine control system – intelligence in the drive
At Baumüller, the servo-hydraulic system is an entirely drive-based solution. This means that the software with all its functions is integrated directly into the b maXX servo drive. This regulates the pressure and flow rate and controls numerous other functions, such as pump monitoring. The switch to a Baumüller drive system is therefore independent of the central PLC and can be combined with products from different control suppliers. This means that the requirements for the central control unit remain unchanged when switching from standard motors to regulated synchronous servo motors. The interfaces for connecting to the machine remain the same. Implementation of the system is vendor-independent and can be achieved with a wide variety of control types.
This is a clear advantage for Hürsan Pres, which uses a different manufacturer for the machine control system of the new press, as specified by the end customer in this case. For example, Baumüller drives can be supplied with the fieldbus option for ProfiNet. Baumüller also offers motion control libraries for Siemens and other manufacturers, making it extremely easy to connect the drive system to a Siemens PLC.
Servo hydraulics independent of the control unit: The servo hydraulics software module is integrated directly in the b maXX 5500 servo drive (left: Mehmet Sarı, Export Sales Manager at Hürsan Pres; right: Özgür Deniz Demirbaş, Country Manager at Baumüller Turkey)
With its b maXX servo drives, Baumüller offers suitable servo drives for high-performance classes. The servo drives impress with their compact installation dimensions and offer a broad and scalable selection of optional safety functions. The devices also have the option of energy recovery.
Motors with very high power outputs are needed in order to provide the high flow rates needed for servo-hydraulic presses. Master-slave load sharing systems are therefore frequently predestined for this application. Baumüller drives offer highly flexible connection methods for this purpose, enabling you to find the solution that best suits your needs.
Partnership from specifications to acceptance
As an international company with a skilled product development team, Hürsan Pres sets the highest standards for its suppliers. Therefore, a dynamic company was sought that would support Hürsan's innovative approach and jointly develop the machine portfolio.
Baumüller is a leading manufacturer of electrical drive and automation systems with over 40 locations worldwide, whose drive systems feature highly dynamic and precise servo technology that ensures maximum efficiency in operation. The drive manufacturer can respond flexibly to customer requirements based on a comprehensive range of hardware and software modules. A perfect partner for challenging projects and future technologies.
Project management based on partnership
Before the project started, the basic parameters, such as the peak torque and the maximum required speed of the motor, were clarified. The next step was to define the most suitable drive system and then adapt the components, including the servo-hydraulic software package, to the requirements of Hürsan Pres. Özgür Deniz Demirbaş, Country Manager at Baumüller Turkey, emphasized that Baumüller worked closely and in close coordination with Hürsan during every phase of the project.
And the results are impressive. The new SERVO press forms with high press force combined with low energy consumption, and precise pressure and flow control. The servo-hydraulic press received such positive feedback that a follow-up order for an even larger press was placed shortly after its premiere.
Innovation through confident cooperation
With the help of the service and application team at Baumüller Turkey, their many years of experience and expertise in drive technology were combined with our specialist knowledge in metalworking. In addition to on-site support, we were also able to draw on the broad application expertise of Baumüller's central application and industry management teams. We work very closely with Baumüller as partners. Partnership means that we actively seek solutions together and also benefit from short communication channels. We are very satisfied with the collaboration."
Mehmet Sarı, Export Sales Manager at Hürsan Pres
Conclusion: Expertise pays off
Lower energy consumption, repeatability, noise reduction, and an innovative drive system: a servo-hydraulic drive has made it possible to combine this wide range of requirements in a single press. And switching to a new drive type was much easier than expected, thanks to drive-based servo hydraulics.
The intensive and confident cooperation between Hürsan Pres and Baumüller created a solid foundation on which each partner could contribute its individual know-how. Baumüller contributes its expertise in servo-hydraulic drive solutions and Hürsan Pres its many years of experience in the press sector.
