2008-07-08 - ABB’s new Dynamic Drive Chain (DDC), designed for sheet metal stamping, is helping manufacturers improve productivity and gain greater yields in stamping thanks to a new industry standard in servo press technology.
By servo driving the presses simultaneously, ABB’s Dynamic Drive Chain synchronizes the loading and unloading actions of the robot with the increased speed of the up and down movement of the press. This new approach enables manufacturers to improve productivity by up to 30 per cent, and reduce cycle times without altering the speed of the stamping process.
The DDC technology aims to serve both new and existing presses, since the complete solution is designed as a self contained product.
The technology is based on proven ABB products like the ACS800 variable speed drive and IRC5 robot controller. It is integrated on the press and consists of a servo motor coupled to a drive system to control the movements of the presses.
Improved productivity
The servo motor enables the press to open and close faster, while maintaining the original speed of the pressing process. From customer trials, feedback has shown it is even possible to stamp at a 40 per cent slower speed than used today, while still improving productivity. This also opens the possibility of using less demanding steel, thus lowering material costs.
One of the key features of the DDC is the introduction of low peak power. As the DDC is a hybrid servo solution that uses the existing flywheel energy of the press, the servo motor and grid peak power requirements are much lower than other full servo solutions. By recycling the energy produced, automation manufacturers can look to reduce their energy consumption while promoting sustainable energy use, as the energy created is transferred to another step in the production line.
Reduced energy consumption
Furthermore, energy consumption is reduced by the removal of the braking and clutching motion of the press. Once the flywheel has completed the pressing required, the energy is passed from the flywheel back to the DCC motor, helping to further reduce energy consumption through continuous production.
Commenting on the Dynamic Drive Chain, Stefan Lampa, Global Manager of Press Automation for ABB said, “As an automation company we are always looking for ways to expand and improve our technology. We had a hard time finding a way to dramatically improve productivity by making the automation run faster without losing quality. When we identified the press as the next step for improvement, we were able to combine our expertise in robotics, drives and motors and create the Dynamic Drive Chain.”
Other ABB press line innovations
ABB’s Dynamic Drive Chain follows other productivity improvements that ABB has recently introduced to press lines. Robotic innovations such as a special press automation robot, seven axis robots and robot synchronization techniques have cut unloading and loading cycle times down from more than six seconds five years ago to less than three seconds today – a reduction of more than 50 per cent.
Lampa continues, “The feedback we have received from our market testing has been very positive, with orders already coming in. We’re excited to see how the sector responds to this technology as a new industry standard for stamping. ”
For more information about the potential benefits of integrating ABB’s Dynamic Drive Chain into your production process, please contact Ramon Casanelles.
ABB Robotics division is a leading supplier of industrial robots – also providing robot software, peripheral equipment, modular manufacturing cells and service for tasks such as welding, handling, assembly, painting and finishing, picking, packing, palletizing and machine tending. Key markets include automotive, plastics, metal fabrication, foundry, electronics, machine tools, pharmaceutical and food and beverage industries. A strong solutions focus helps manufacturers improve productivity, product quality and worker safety. ABB has installed more than 160,000 robots worldwide.