Danish pump manufacturer Grundfos has achieved a major technical advance with a completely newly developed servo press. The system combines precision, user-friendliness and cyber security, while energy consumption per stroke has been reduced by up to 85%.
© AP&T
Energy efficiency, high repeatability and free programmability were among the main requirements when Grundfos wanted to modernize a central part of its production of metal components for its pumps. The system was the result of a collaboration with the Swedish press manufacturer AP&T. The globally unique system is now in operation in Bjerringbro, Denmark, as the press manufacturer reports.
“As far as we know, there is nothing like it anywhere else in the world. The press is freely programmable, can control the respective motor and pump separately for each cylinder and has amazing precision, as it can synchronize 4000 times per second. We could hardly believe the figures ourselves when we saw them for the first time,” says Peter Karlsson, Key Account and Area Sales Manager at AP&T.
Grundfos project manager Peter Lund Pedersen describes the initiative as a strategic step in the company’s sustainability work. “Our aim was to future-proof the cold extrusion process. We initially considered an overhaul of the control system, but when we saw the potential energy savings and process benefits of a new servo press from AP&T, the decision was easy,” he says.
50 years of joint experience in technical development
The relationship between AP&T and Grundfos was crucial in the development. The collaboration began back in the 1970s and has led to several innovations. “Grundfos is a demanding customer. Our collaboration has been a driving force in our development,” says Karlsson.
Grundfos also emphasizes the importance of mutual understanding. “What makes our partnership successful is our shared willingness to try out new methods. We have a good and open dialog and have always been in agreement when developing new production technology,” explains Lund Pedersen.
The new servo press is integrated with two other machines from AP&T in an automated system. All are connected to a visualization system that displays energy consumption in real time, both for each individual machine and for the entire process.
“This new servo press consumes significantly less energy than the older machines. It is ten times more efficient than the old machines,” says Karlsson.
Grundfos itself has added an external screen to the system, which displays the energy data directly in production. “The visualization has taken on an important function in our work. We use it to quickly identify deviations and drive improvements. It provides a strong visual effect, especially compared to the older presses. We have a Green Team that works on identifying energy savings,” says Lund Pedersen.
© AP&T
Programming freedom and operation with less noise
Another feature of the press is the freely programmable user interface. It allows the operator to control and adjust pressures, sequences and cycles themselves without the need for external programming. “It saves an enormous amount of time and increases production capacity,” says Karlsson. “Free programmability is crucial for our production. It gives the operators control and enables a quick response to production changes,” adds Lund Pedersen. Noise emissions have also been reduced to 67 dB(A). “Minimizing noise is always a goal when we invest in new equipment. The new press has significantly improved the working environment,” he says.
With digitalization, cyber security is also becoming more important. AP&T’s recent ISO 27001 certification was therefore an important criterion for Grundfos. “We require our suppliers to comply with security standards, especially in the area of IT security,” says Lund Pedersen.
In operation and high expectations fulfilled
The servo press is now in operation and the results of the first few months are in line with expectations, both in terms of technical performance and energy efficiency.
“There is always a certain run-in period with new technology, but now the machine is running stably in production. The precision, noise level and energy consumption are exactly as we had hoped,” says Karlsson happily.
At Grundfos, clear results can already be seen. However, Lund Pedersen also says that the real effects will only become apparent in the longer term. “The most obvious result is the energy saving, especially compared to the previous press. We will only be able to assess further results when we have the press in operation for longer,” he says.
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