Energy-saving servo press with precise control
Servo presses are ideal for creating different joints, for example by press fitting, caulking, riveting, stamping, clinching, and much more, thanks to their control options and variable stroke lengths.
Servo-electric presses from IAI are used in automatic production systems as well as in manually controlled workstations. Typical applications are in the automotive sector as well as in the production of medical and electronic products and in the household appliance industry.
Depending on the model, the press force of IAI servo presses ranges from 24 N to 50 kN, with a stroke length between 100 mm and 500 mm. Almost all of them can be ordered in stroke length increments of 50 mm. An RCP6 servo press can be used for both push and pull movements.
The TÜV-certified safety monitoring functions of the SCON2 controller enables servo presses to be operated without a protective fence or emergency shutdown of the drive source. The functional safety unit monitors ongoing operation and safely shuts down the servo-electric press in case of danger.
Optimal servo press for thrust operation
RCS3 servo spindle presses are characterized by their precise positioning control, simple thrust force adjustment, and accurate position monitoring. They ensure high holding stability during press assembly and are therefore ideal for thrust operations.
The thrust force adjustment and position monitoring are based on the feedback data from the built-in load cell. It records the force acting on the press object and enables precise force control with a repeat accuracy of ± 0.5% of the full scale (FS) deviation.
The IA-OS software (PC Software) includes eight different press assembly programs for RCS3 and RCS2 servo presses, which can be used for a wide range of press movements. You can choose between the control modes “speed control” or “force control.”
In addition, a hold method can be selected from the four stop conditions “Position,” “Travel,” “Load,” or “Incremental Load.”
The TÜV-certified safety monitoring functions of the new SCON2 controller enable the use of RCS3 and RCS2 servo presses without protective fencing or emergency shutdown. When people approach, the servo press is safely stopped without interrupting production.
For more information about the SCON2 controller and its integrated safety functions, see: Controllers
In addition, all SCON controllers have interfaces to fieldbus networks. The target position, speed, acceleration, etc. are entered into the controller via corresponding position numbers and then specified externally for axis operation via input/output signals.
A wide range of functions have been integrated for preventive maintenance. Among other things, temperature fluctuations in the motor are continuously monitored and a warning signal is triggered if motor overload is detected. In addition, the number of cycles is recorded along with the distance traveled in order to monitor maintenance cycles.
All IAI servo presses are equipped with high-resolution, battery-free absolute encoders. Their advantages are that no reference point has to be approached during commissioning after an emergency shutdown or operating error and no home sensor is necessary.
In addition, there is also no need for maintenance and replacement of the back-up battery, which is used for position storage.
Advantages of battery-free absolute encoders
- No reference point travel
- No external home sensor
- No workpiece removal after an emergency stop
- No battery change, no battery disposal
Servo presses are increasingly replacing conventional hydraulic or pneumatic presses. The technological decision is usually based on the better energy balance, precise controllability, and greater flexibility.
1. Precision and repeatability
- Servo drives enable very precise force and position control.
- Typical repeatabilities are in the range of ±0.01 mm or better.
- Ideal for applications with high quality requirements (e.g., in electronics, automotive, or medical technology).
2. Process monitoring and documentation
- Servo presses measure force and displacement in real time.
- The entire joining process can be recorded, analyzed, and documented.
- This enables 100% process monitoring and traceability.
3. Energy efficiency
- Energy is only consumed during the joining process.
- No pumps or compressed air generation as with hydraulic/pneumatic systems.
- This results in significantly lower energy consumption and operating costs.
4. Cleanliness and low maintenance
- No oil, no leaks, no hoses – the system is clean and environmentally friendly.
- Maintenance requirements are significantly lower than for hydraulic systems.
5. Flexibility
- Force, displacement, and speed profiles are freely programmable.
- One system can perform several different joining tasks.
- Ideal for flexible manufacturing and frequent product changes.
6. Low noise and compact
- Significantly quieter operation without a hydraulic unit.
- Compact design, as no separate unit or tank is required.
Pulse press for push and pull operation
The RCP6 pulse press is an actuator combining a stepper motor and load cell, that is capable of performing power control. It provides a loading repeatability of ±1.0% F.S. (full scale), based on feedback from the load cell.
Both pushing and pulling operations are supported in the load direction. There are no limitations on pushing or pulling times.
