AUTOMATION Among the system’s highlights:


• Dual axis actuator - Promotes fast ram travel and high pressing forces using minimal energy.


• Proprietary clutch system - Utilising optimal acceleration and deceleration profiles enables a smooth, energy efficient transition between servo axes.


• High torque (high force) axis - Has a 10:1 gear ratio to achieve high pressing forces with minimal energy consumption.


• Roller screw technology - Carries larger loads and higher speeds more efficiently.


• Optimised coil construction - Allows for high-density coil packs without extraneous magnetic field generation to reduce the physical size of the actuator and increase motor efficiency.


• Regenerative/dynamic braking - Captures inertial energy and applies it to deceleration for substantial reduction in the system’s external energy requirements.


• PC control - Utilises only the hard drive for machine setup. During a run, all logic is maintained by solid-state memory in the system’s servo controllers. This is inherently energy- efficient, because the PC moves into idle, or ‘sleep’ mode after setup.


Typical press cycle Here’s a step-by-step look at how the press system works


in practice to conserve energy during the fastener installation process: The operator sets up the press via the PC, which passes


the setup instructions to solid-state servo drive memory modules and then reverts to a ‘standby,’ totally idle condition (consuming less energy). The operator next initiates the press cycle using a foot pedal


and the ram begins to travel down. Because of low internal friction, low initial load, and the effects of gravity, very little energy is required to accelerate the downward movement of the ram. As the ram approaches the pressing position,


it begins to decelerate and the high torque motor (high force pressing motor) begins to accelerate. Due to the design and function of the unique clutching system, the high torque motor seamlessly takes control of the ram travel and presses with high force. Very little energy is required for the pressing, given the 10:1 gear ratio and short pressing distance. When the preset force is achieved,


the high torque motor is reversed and the high speed motor begins to accelerate. The high speed motor takes control and the ram begins upward movement. The low inertial load minimises energy required to move the ram up. As the ram approaches the top home


position, the regenerative/dynamic brake is applied, which halts travel of the ram. No external energy is required to stop the ram, because the regenerative braking creates its own energy from the motion of the high-speed motor.


Numbers tell the story The inherent efficiencies of this servo-driven system deliver


a cost-effective solution for sheet metal fabricators striving to ‘go green’. An added benefit is that multiple types of self- clinching fasteners can be installed automatically without any need for tooling changeovers. In an effort to decisively quantify energy savings compared


with ‘non-green’ hydraulic press equipment, a reputable testing house was recently selected to conduct an independent study of the Series 3000 press. The study reported the following statistics: Running at 40 strokes per minute, the Series 3000 press


system was documented to consume less than £25 (30 euros) of energy annually in producing 4.9 million fastener insertions. In contrast, a typical 8 tonne hydraulic press running at only 15 strokes per minute uses more than £540 (648 euros) of energy to produce 1.4 million fastener insertions. These numbers tell a compelling story. The electro-


mechanical press effectively was shown to consume 20 times less energy while producing 3.5 times the insertions, compared with hydraulic systems. In short, the conclusion is that it would cost more than £1,930 (2,318 euros) annually for energy alone to run a conventional 8 tonne hydraulic press and produce the same amount of strokes delivered by the more efficient Series 3000 system, according to the study.


Footnote: The energy usage reported here was based on straight-line calculations from the independent study and grounded in a relatively low energy cost of £0.06 per kW/hour. Even better news: Higher electricity costs would bolster the outcome by equating to even greater energy cost savings for fabricators seeking to relieve headaches and advance ‘green’ objectives on the shop floor.


16 Fastener + Fixing Technology • Issue 5 Apr - Jun 2012


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