Servo Motorized Pump Hybrid Press Brake

Servo Motorized Pump Hybrid Press Brake


With the wide application of bending machine equipment, for the use of hydraulic equipment industry, power consumption is an important part of its production cost, and bending machine is one of the main energy consumption equipment, so reducing the energy consumption of bending machine has become an effective way to reduce costs and improve product competitiveness.

  1. Energy saving principle of frequency conversion,

    Press brake motor running with frequency Inverter

    The electric energy consumption of the bending machine is mainly reflected in the electric energy consumption of the hydraulic system oil pump,

    The power consumption of hydraulic oil pump accounts for more than 97% of the total power consumption of hydraulic press, so reducing its power consumption is the key to energy saving of hydraulic press. The pressure and flow required by the hydraulic press in the fast down, slow down, pressure maintaining, pressure relief return, piston ejection, piston return, buffer cylinder ejection and other stages are all changed. When the oil demand of the bending machine changes, the overflow valve at the outlet of the oil pump adjusts the load pressure and flow, while the output power of the motor is unchanged, resulting in energy waste.

    The variable frequency speed regulating device is composed of rectifier circuit, filter circuit, inverter circuit and control circuit. Its function is to convert the alternating current energy into direct current energy through rectifier and filter, and then convert it into alternating current energy of different frequency through inverter to output to the motor. Therefore, the hydraulic oil pump motor can work at different speeds.

    The oil flow of oil pump is proportional to the rotation speed of oil pump motor, and changing the rotation speed of oil pump motor rotor is realized by automatically controlling the output frequency of frequency conversion energy-saving speed regulating device with the synchronous signal of hydraulic machine

    The bending machine can be roughly divided into ten processes: starting, sliding block fast downward, sliding block slow downward, sliding block pressure maintaining delay, sliding block pressure relief delay, sliding block return, stop. Each process in turn needs to use different working pressure and flow. In addition to the high pressure used for slow downward, other processes work under very small pressure, and their pressure and flow are regulated by pressure hydraulic valve, but For the ordinary bending machine, the installation of frequency converter only controls the speed of the main motor and plays a role of soft start. It only reduces the energy waste in the process of starting and standby of the bending machine. In the process of machine operation, it can reduce the running speed of the main motor and realize the conversion between torque and speed. The effect of energy saving is not very obvious, especially For small bending machine, the effect of frequency conversion and energy saving is not obvious.

    Features of frequency conversion and energy saving bending machine:

    1. Can reduce energy consumption:

    The frequency conversion cabinet of bending machine is used to change the traditional quantitative pump into variable pump, and the frequency conversion speed regulation method of high-pressure and low-pressure double signal input is used to replace the previous valve speed regulation method, thus greatly reducing energy consumption.

    2. Improve the production process and extend the service life of the equipment:

    The energy-saving cabinet device of hydraulic press adopts external extended synchronous control, and any speed section can be adjusted at will, which can meet the requirements of hydraulic process conveniently, make it reach the best value, and improve the production process. Moreover, it can reduce the oil temperature of the system, prolong the service life of the sealing elements and reduce the maintenance cost of the equipment.

    3. Convenient control and operation:

    The energy-saving cabinet device of the bending machine adopts advanced computer control means, uses the synchronous signal of the hydraulic machine computer, and automatically controls the oil pump motor according to the technological requirements of the bending machine. The operation is safe and reliable. In the production, the energy-saving cabinet of the hydraulic machine does not need to be adjusted, and the control operation is convenient and simple.

    4. Without throttling energy loss, overflow energy loss is greatly reduced, so that the system noise is reduced by 3-5 decibels, oil pipe heating is reduced, and oil temperature is reduced.

    5. Realize soft start in full sense:

    6. High reliability:

    The speed regulating device of bending machine energy-saving cabinet can realize power frequency / frequency conversion, even in case of frequency conversion failure, it can be converted to power frequency without affecting the production progress. Large lifting torque, fast dynamic response, suitable for sudden speed up of hydraulic press.

    7. Frequency conversion and energy saving are low efficiency and simple in energy saving effect, but they are more economical and can make less noise

     

    (2) Hybrid CNC Press brake, we also called servo motorized Hybrid press brake , double servo pump cnc press brakes or servo oil flow variable pump cnc press brake

    Principle of electro-hydraulic servo hybrid drive pump controlled electro-hydraulic servo numerical control device:

    The pump controlled servo CNC bending machine includes a power source and a control valve group connected with the CNC system, which is characterized in that the power source includes a servo motor, a bidirectional quantitative pump and an oil tank connected with the servo motor; the control valve group includes a shuttle valve, a pressure valve and a unloading valve regulating the system pressure, as well as a check valve, a reversing valve, a back pressure valve, a lifting valve, a safety valve and a filling valve; the bidirectional quantitative pump The inlet and outlet of the two-way quantitative pump are controlled by shuttle valve, the forward outlet is directly connected to the upper chamber of the oil cylinder, the reverse outlet is connected to the lower chamber of the oil cylinder through lifting valve and back pressure valve; the inlet and outlet of the two-way quantitative pump are connected to the oil tank through one-way valve, reversing valve and filling valve; the filling valve is connected to the control valve; the oil tank and the lower chamber of the oil cylinder are connected with safety valve. It has the characteristics of high efficiency, energy saving and high synchronization accuracy.

    By changing the displacement of the two-way variable displacement hydraulic pump, the two-way quantitative hydraulic motor is regulated. The displacement adjustment of the variable displacement pump is realized by the displacement adjustment of the valve controlled electro-hydraulic servo valve mechanism composed of the electro-hydraulic servo valve and the double rod hydraulic cylinder. A speed measuring motor (speed sensor) is set between the load and the command mechanism to form a closed-loop speed control system. When the command signal is input to the system, the pressure oil controlling the hydraulic source supplies oil to the double rod hydraulic cylinder through the electro-hydraulic servo valve, which makes the variable mechanism of the hydraulic cylinder driving the variable pump work in a certain position; the output speed of the hydraulic motor is detected by the speed measuring motor, which is converted into the feedback signal, and compared with the input command signal, the deviation signal controls the valve opening of the electro-hydraulic servo valve, Thus, the displacement of the variable displacement pump is kept near the set value, and the two-way quantitative hydraulic motor can work near the desired speed. The position sensor constitutes the internal feedback link to improve the control accuracy of the system.

    (2) The comparison between the pump controlled electro-hydraulic system and the transmission mode of the electro-hydraulic servo hybrid drive:

    (3) Advantages of electro-hydraulic servo hybrid drive pump control electro-hydraulic system:

     

    This YAWEI PBM ePrAX Hybrid press brake systems is the consistent further development of servo driven press brake systems 

    from HOERBIGER. Hybrid press brake machine using one variable speed servo 

    motor pump to drive&control real position and bending pressure in time 

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AHYW YAWEI PBM Main Electro Hydraulic structure of Hybrid Press Brake Machines:

AHYW Hoerbiger ePrAX hybrid system mounted directly on top of Y1&Y2 cylinders;

valves, pump,servo drive and oil tank are compactly integrated in the ePrAX.

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1, Y1 servo hybrid, including tank, servo drive and valves

2, Y2 servo hybrid, including tank, servo drive and valves

3, Italy Phase servo drive for Y1&Y2 hybrid system

4,Y1&Y2 cylinders

AHYW YAWEI PBM Main working principle of ePrAX 4m Hybrid Press Brake Machine:

DELEM DA58T 2D graphical AHYW CNC Press brake controller can calculate the needed pressure for bending specific profiles automatically, 

CNC will give command to servo motor&drive reach required rotation speed with needed oil flow to 

complete one bending cycle using speed variable motor-pump unit; while two units linear scale monitor ram position in real time and feedback to CNC constantly. 

Variable motor-pump only working if press bending, almost stop when in standby stage and material handling stage.

 AHYW Customer benefits of 4m  YAWEI PBM CNC Hybrid Press Brake Machines (Compared with Traditional 

AHYW Synchro Hydraulic press brakes&Electrical press brakes machine)

1, Reduced cycle time at same speeds

Pressbrake ram approach -mute-bending-decompression-return , 100T4m Hybrid press brake machine can save up to 30% cycle time

2, Eco-friendly

  1. When you are considering purchase a hybrid press brake, the first thing to look at is energy savings. 

  2. Using Hybrid servo brakes press 4M/100T as an example, 

  3. customer can get a 62% energy savings while in standby mode, 

  4. 44% savings during the press cycle and 60% savings over one hour. 

3,Quietest 

  1. One thing that we love Hybrid press brake machine is that when 

  2. it’s in standby mode and not moving when handling bending material,

  3.  it’s running silently, fully noiseless

4,Ease of application&maintenance

  1. Y1&Y2 have independent oil tank, all hydraulic components are integrated in Hybrid system, 

  2. no need hydraulic expertise

5, Less of oil consumption

  1. Oil capacity at 34.5L*2 units, no need to change oil within 7000 working hours

6, Less of electricity consumption

  1. Servo variable speed motor-pump won’t running if operator do not press pedal

7,Accurate

  1. ePrAX Servo Hybrid press brakes are much more accurate than standard hydraulic brakes press machine. 

  2. Each side of a ePrAX hybrid press brake is independently operated by its own hydraulic system, 

  3. with each cylinder having its own servo motor and valve controlling it. 

  4. Beyond the accuracy of the scale hybrid pressbrakes have each servo motor measuring and 

  5. controlling the amount of fluid that were pushing through the valves.

  6. So it’s more controlled, on command, like a direct drive system. 

  7. It’s very fast and very accurate.

8, Oil don’t heat up

9, Higher Bending efficiency

  1. Highest bending efficiency is achieved as no pressure is lost without proportional valves.

10, Lower cost than full electrical press brake machine

Main images of Hoerbiger ePrAX YAWEI PBM 4M Hybrid press brake 100T 5 axis Bending machine  AHYW Yawei manufactures China

Italy Phase main servo motor to control variable speed pump running

Yaskawa servo motor for X&R 2 axis cnc auto back gauge for 100T4M PBM synchro press brakes AHYW Yawei China

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