FEATURE u Machine Building
Environmentally-friendly and cost effective Servo Press Systems
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nterference fit has been used for many years 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. The problem with these systems is lack of flexibility; once installed for a particular operation changes are both time consuming and expensive. In recent years, industry has been switching to the new generation of electromechanical actuators to take advantage of the cost savings of around 77 per cent over hydraulic and 90 per cent over pneumatic systems. These savings accrue from increased productivity, lower maintenance and greatly reduced energy costs and result in a remarkably short payback period in the majority of applications. A major advantage is that because they need only an electrical supply the risk of work space contamination is eliminated.
INCREASED PRODUCTIVITY 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. These 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 approach 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. Importantly, the control program can be easily changed, allowing electromechanical actuators to be used on a different press fit operation in a different location, making the system flexible and cost effective.
LOWER MAINTENANCE Electromechanical actuators require very little maintenance, typically less than one man-hour per actuator per year. Compare this to the needs of hydraulic and pneumatic systems which demand fixed pipework and compressors, needing 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.
INSTALLATION COSTS The initial investment into electrical technology is greater than hydraulic or pneumatic technology. However, there are other important factors besides the initial investment. The Kistler Servo Press design is compact and low weight. This makes the system easy and inexpensive to install, especially in difficult locations, 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 versatility allows production planners flexibility in the design of the manufacturing process; plus, the electromechanical system is quieter and cleaner than hydraulic or pneumatic systems – a major environmental advantage.
LOW ENERGY COSTS 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, 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 total savings, from lower energy consumption and reduced operating and maintenance costs, to give a payback period of as little as eighteen months which is more than enough to win over most financial directors. Apart from low energy consumption,
production engineers value the versatility of the electromechanical Servo Press Systems. Even a manufacturing process with a relatively small number of press-fit operations can benefit from the installation of a simple, low cost system which will quickly pay for itself. Kistler Instruments
www.kistler.com
Riveting machine for lightweight brake disks 32 November 2021 Irish Manufacturing
Overall view of the lightweight brake disk riveting machine
www.irish-manufacturing.com
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