How Energy-Saving Servo Presses Will Power Your Net Zero Goals

Introduction

The threat of climate change has amplified the need to reduce carbon emissions. In 2015, 196 countries adopted Paris Agreement and set the goal to hold “the increase in the global average temperature to well below 2°C above pre-industrial levels” and pursue efforts “to limit the temperature increase to 1.5°C above pre-industrial levels.” However, to limit global warming to 1.5°C, greenhouse gas emissions must peak before 2025 at the latest and decline 43% by 2030, according to UN’s IPCC. Meanwhile, Net Zero emissions (cutting greenhouse gas emissions to as close to zero as possible, with any remaining emissions re-absorbed from the atmosphere) must be reached by 2050. As 198 countries and 713 regions have declared their own Net Zero goals, many industries have decided to lower their carbon footprint. Specifically in the automotive industry, the primary mission of many OEMs is to complete a full lineup of electric vehicles.

In addition to Net Zero issue, we foresee EV development to evolve rapidly as hundreds of models will launch within the next few years. As a result, the manufacturing needs will increase significantly, requiring faster and more intelligent manufacturing. Smart machineries like IoT technology and data-oriented production will help achieve this vision.

Energy Efficiency through Servo Presses

The use of servo presses in metal stamping is becoming increasingly popular due to their energy-saving advantages and forming abilities. Reducing energy consumption and material waste contributes to carbon reduction, helping manufacturers achieve a balance between emitting and absorbing their carbon. The adoption of the servo press will be a significant step for environmental protection.

1.   Direct-drive transmission

SEYI’s servo presses are designed by the environmental-friendly and energy-saving concept. A direct-drive design was adopted without flywheels and a deceleration mechanic. The servo motor integrates the pinion shaft directly into the motor. Thus, reaching better accuracy and energy efficiency for a press. Meanwhile, This direct-drive motor type can increase speed and stroke optimization with much less vibration throughout the process, enhancing end product quality and productivity.

2.   In-house designed servo motor

Different from commercial servo motors, SEYI's servo motors are developed in-house and are specifically designed for a stamping press. This allows SEYI's servo motors to offer the precise control of slide movement and improve forming speed. Unlike traditional high-speed servo motors, SEYI's low-speed, high-torque motors do not need a speed reducer to compensate for high speeds and energy loss. As a result, a SEYI servo press can form high-strength steels, aluminum, and other difficult-to-form materials with less spring-back and a much lower tool wear rate.

Servo motors can also regenerate power. When the electrical energy converts into mechanical energy for machine movement, the reaction of the movement can convert mechanical energy into electrical energy. Traditionally, resistors are used to consume the electrical energy. However, capacitors allow power to be stored and recycled. Another feature of our SEYI's motor design is its air-cooled system, which is more efficient than a water-cooled one. SEYI's servo press's power consumption is up to 70% less than a mechanical press (the percentage depends on customers’ production conditions). With SEYI's servo motor, you can save money on your power bill and lower your factory's carbon footprint.

3.   Power leveling

The instantaneous peak current typically occurs during the stamping process. Via PU, the voltage of power source can still be stable without a sudden increase.

4.   Low noise

With controllable slide motion, the stamping noise will decrease by at least 15dB compared to the stamping noise on a mechanical press. This allows the working conditions to improve along with enhanced manufacturing.

Reduced Waste through Servo Presses

An optimized stroke allows a servo press to reduce significant material waste when manufacturing. By programming the slide velocity, position, and force, manufacturers can lower the amount of scrap in their production. This precision eliminates the need for secondary operations and reduces waste. Thus, manufacturers will need less equipment in their operations. Reducing material waste minimizes the carbon footprint and supports the carbon reduction goal.

Conclusion

Servo presses in the manufacturing industry are a sustainable approach toward the Net Zero goal. Their energy-saving advantages reduce carbon emissions, and the precise control of the stroke minimizes material waste. Many governments have regulated energy-saving policies and offered subsidy programs for manufacturing process improvement, energy conversion, and circular economy. One method is to replace old machines with new energy-saving equipment. For example, the German government encourages local manufacturers to implement low-carbon equipment to reduce carbon emissions and enhance production efficiency.

One customer in Ruhr, Germany, demonstrated the benefits of new machines. The annual power consumption of its original hydraulic press line was nearly 150,000 kW. After changing to servo presses, the power consumption fell to 50,000 kW per year, in addition to doubled outputs. The company found that its estimated 10-year profit will increase 400 percent after switching to servo presses. This success case also strengthened SEYI’s mission on developing environmental friendly green products. At the same time, SEYI thrives to reduce carbon emissions at its factory to improve manufacturing process in a sustainable and responsible way, together with SEYI’s customers for a better planet.

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