Servo press leads intelligent manufacturing upgrade: the green revolution in the era of hydraulic press
In the wave of industrial manufacturing moving towards intelligence and greenness, a revolution about "power" is quietly taking place. The stamping and forming field, which was once dominated by hydraulic presses, is now welcoming a more efficient and precise "receiver" - servo presses. This equipment iteration is not only related to technological upgrading, but also a key step for enterprises to respond to the dual carbon target and enhance their core competitiveness.
The pain point of hydraulic press: the shackles of traditional mode
Over the past half century, hydraulic presses have become standard equipment in fields such as automotive parts, home appliances, aerospace, etc. due to their strong power and simple structure. However, with the increasing demand for precision and flexibility in the manufacturing industry, the shortcomings of hydraulic systems are becoming increasingly prominent: high energy consumption (continuous power consumption in standby mode), severe noise pollution, risk of oil leakage, and precision bottlenecks limited by mechanical structures. The production manager of a certain household appliance enterprise admitted, "The annual power consumption of a single hydraulic press is as high as 100000 kWh, and the fluctuation of processing accuracy often leads to a product qualification rate of less than 95%. The pressure to upgrade is urgent
The Breakthrough of Servo Press: Technological Leap of Digital Drive
The core breakthrough of servo press lies in upgrading the traditional hydraulic/mechanical transmission to a closed-loop system of "servo motor+digital control". Real time monitoring of pressure, displacement, velocity and other parameters through high-precision encoders, combined with advanced algorithms to achieve micrometer level control, improves machining accuracy to over 99.8%. More noteworthy is its energy-saving feature: actual test data from a new energy vehicle parts manufacturer shows that servo presses reduce energy consumption by 62% under the same production capacity, and reduce no-load losses through the "start stop" mode, saving over 80000 yuan in electricity bills per unit annually.
At a precision bearing manufacturing base in Zhejiang, after 20 newly invested servo press units were put into operation, the production line demonstrated astonishing flexibility. Now switching product models only takes 3 minutes to adjust parameters, reducing the scrap rate from 5% to 0.3%, and automatically generating process big data. Engineer Wang Ming displays an intelligent dashboard, where the system analyzes the pressing curve of each product using AI and provides early warning of mold wear.
Policy Dongfeng accelerates industrial renewal
The 2023 Action Plan for Industrial Energy Efficiency Improvement explicitly requires that energy consumption in key industries be reduced by more than 13% by 2025. Local governments have successively introduced subsidy policies for the elimination of hydraulic equipment, and a development zone in Jiangsu has provided a special subsidy of 15% for the procurement of servo presses. This has driven the servo press market to grow at an average annual rate of 21%, and it is expected that the market size will exceed 12 billion yuan by 2025.
The layout of industry leading enterprises is more forward-looking: the latest third-generation servo press integrated IoT module launched by Schuler Group in Germany can achieve remote diagnosis and predictive maintenance; The domestic manufacturer Yangli Group has developed modular servo presses for small and medium-sized enterprises, with a shortened investment payback period of 2.3 years. The first batch of 200 devices were pre ordered as soon as they were produced.
Future Vision: From Device Upgrades to Manufacturing Paradigm Transformation
The popularization of servo presses is restructuring the production logic. Through device networking, real-time interaction between pressure curve data and MES system transforms quality control from "post inspection" to "process control"; The digital precipitation of process parameters provides machine learning samples for process optimization. The director of Sany Heavy Industry Intelligent Manufacturing Research Institute pointed out, "This is not just a simple equipment replacement, but opening up the interface to Industry 4.0
In the context of carbon neutrality, the energy-saving benefits brought by servo presses are giving rise to new business models. A certain die-casting enterprise will profit from the carbon quota saved through the carbon trading market, and will receive an additional profit of 870000 yuan in the first year. This closed-loop of "technology emission reduction carbon asset realization" allows green investment to be converted into real money.
This silent workshop revolution is reshaping the genes of Chinese manufacturing. When the buzzing of servo motors replaces the buzzing of hydraulic pumps, what we see is not only a drop in energy consumption statistics, but also a firm footprint of the industry's transition towards precision and intelligence. Perhaps in the near future, hydraulic machines will become an important footnote in the evolution of intelligent manufacturing, just like steam engines entering museums.
