Extrusion presses remain a critical cornerstone of manufacturing, with many having been in operation for decades. Despite their longevity, presses may not be operating at peak efficiency due to wear and tear of individual components. This can obviously impact productivity and ultimately, a manufacturer's bottom line. Beyond typical maintenance, operators must routinely evaluate whether their presses need to be replaced or if drop-in solutions exist to extend the life of their operational workhorses.
One of the central components of many presses is the hydraulic pump, which can be susceptible to leaks and loss of efficiency over time. The repairs on pumps can be costly, both financially and in downtime spent addressing the issue. Compounding the problem is that finding replacement pumps for older presses is becoming increasingly difficult. As such, there is now a premium on implementing solutions that can seamlessly integrate with older presses while increasing productivity and avoiding an entire press replacement.
A company in Michigan recently implemented such a solution for its direct aluminum extrusion press that has been in operation since the early 1970s. The pumps on their press were becoming outdated and expensive to repair. The pump/manifold/controls solution that Rexroth designed underwent more than 150 hours of testing to validate operation at the full range of temperatures, flowrates and pressures. A subsequent test was run for 100 hours at full flow and full pressure, followed by a complete teardown and inspection that showed no significant wear or damage. The pump was then installed on an extrusion press for 2,000 hours of real-world production, followed by another teardown and inspection that validated its suitability for the demanding application on an extrusion press. Perhaps most importantly, the axial piston pump, manifold circuit and valves that were at the heart of the solution were inserted seamlessly and preserved the existing press piping. Also, the retrofit was completed in a weekend, which reduced the amount of downtime spent upgrading the press.
The impact for the company was multifaceted. It saw a 14% increase in productivity, which equated to nearly 2 million more pounds of aluminum extrusion per year. Equally as impressive was the sustainability impact. The retrofit press required less energy and led the company to switch out the motors for lower power, more energy-efficient ones. Plus, the oil temperature needed dropped by 5-10°, which allowed the press to operate at a cooler temperature. Finally, oil leaks were also reduced, which saved the company money and downtime on repairs, which are becoming increasingly more expensive.
Sustainability remains a top concern for many manufacturers as they are constantly evaluating processes and seeking ways to maximize efficiency at a minimal impact to their budgets and downtime. Extrusion presses represent a unique microcosm of those evaluations, as many are operating with outdated technology and components. But as the above case study illustrates, there is inherent value to considering retrofit efforts that can not only improve productivity, but save manufacturers money and create sustainable processes that benefit both OEMs and customers alike.
Authored by Michael Kramer, Bosch Rexroth Press Application Engineer
For more information contact:
Bosch Rexroth Corporation
14001 South Lakes Drive
Charlotte, NC 28273
704-583-4338
www.boschrexroth.com/en/us