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FEATURE MACHINE BUILDING, FRAMEWORKS & SAFETY
For many years, hydraulic and
pneumatic actuation has been used on
servo press systems. In recent years, however, industry has been
switching to the new generation of
electromechanical
actuators. Here, Kistler explains why
F
or many years, interference fit has been used as a simple and reliable method of joining two components of a sub-assembly,
typically on automobile transmission and gearbox assembly lines where gears, bearings and bushes are pressed onto shafts. Historically, hydraulic actuation has been used for interference fit operations, with pneumatic actuators or mechanical cams being used for low force applications. But, once such systems are installed for a particular operation, changes can be time consuming and expensive. More recently, industry has been using the
new generation of electromechanical actuators in order to take advantage of the cost savings of around 77% over hydraulic and 90% over pneumatic systems. These savings accrue from increased productivity, lower maintenance and greatly reduced energy costs, and result in a very short payback period in the majority of applications. Furthermore, as they need only an electrical supply, the risk of work space contamination is eliminated.
fLExIbILITy
The key to increased productivity is the reduction or, in many cases, the elimination of rejects due to the precision and ease with which the whole process may be monitored and controlled in real time. Kistler's electromechanical Servo Press Systems have integrated sensors to allow efficient analysis for comprehensive process monitoring and the documentation of all measurement values. The electromechanical actuators from Kistler
include both force sensors and rotary encoders to measure and control the operation, with the actuator linked to a servo controller and a program/monitor unit. This makes it possible to accurately specify a series of force, position and speed combinations which clearly define a number of steps in a process. A position repeatability of <0.01mm is possible
and, for some applications, force feedback may be used to provide a level of control greatly exceeding that of hydraulic or pneumatic systems. In addition, the control program can
18 DESIGN SOLUTIONS APRIL 2022 SWITCHING TO
ELECTROMECHANICAL ACTUATION
Two Kistler NCFN Type 2153A servo press units used in this application allow riveting of up to 20 types of lightweight brake disks
be easily changed, allowing electromechanical actuators to be used on a different press fit operation in a different location, making the system both flexible and cost effective.
THE bENEfITS
Electromechanical actuators require very little maintenance, typically less than one man-hour per actuator per year, whereas hydraulic and pneumatic systems, which demand fixed pipework and compressors, need regular servicing. In the case of the hydraulic systems, additional maintenance costs are incurred by the need to change the hydraulic fluid at regular intervals and the safe disposal of the used oil. Although the initial investment into electrical
technology is greater than hydraulic or pneumatic technology, there are other important factors besides the initial investment. The Kistler Servo Press design is compact and low weight, meaning it is easy and inexpensive to install, and is ideal for interfacing with robotic systems. For example, a 15kN actuator module is just 520mm long, with a mass of 17kg, and can be easily relocated should the need arise. This therefore provides flexibility in the design of the manufacturing process. In addition, the electromechanical system is significantly quieter and cleaner than hydraulic or pneumatic systems which can be a major environmental advantage. All manufacturing companies are seeking lower energy consumption to lower production
costs and minimise impact on the environment. Installed in place of hydraulic or pneumatic systems for press-fit applications, electromechanical actuators can generate significant energy cost savings, which deliver rapid cost recovery, improved working conditions and reduced pollution. Electromechanical systems use energy only
when performing pressing operations, do not use oil and have very low maintenance requirements. A press-fit production line using Kistler electromechanical Servo Press System actuators can generate savings from lower energy consumption and reduced operating and maintenance costs, to give a payback period of as little as eighteen months. Electromechanical Servo Press Systems also
offer versatility – even a manufacturing process with a relatively small number of press-fit operations can benefit from the installation of a simple, low cost, electromechanical system which will quickly pay for itself. The combination of higher productivity, easy
installation, low maintenance and minimum energy consumption, combined with better working conditions, make installing a Kistler Servo Press System a real world win-win situation, the company concludes.
Kistler Instruments T: 01256 741550
www.kistler.com/en/
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