May 2025 Volume 7

EQUIPMENT & TECHNOLOGY

Further improving efficiency is the use of VFD motor controls. With the use of VFD motor controls, hydraulic pump motors can be slowed or idled when not in use. Idling the motors avoids the inrush current from stopping and starting the motors. Idling the motors also reduces noise, pump wear and cooling requirements. When VFD controlled motors are used in combination with “smart” variable displacement pumps, press velocity and control functions are more efficient than resistive throttling. Mechanical presses can also benefit from the use of VFD controlled motors. With NEMA C&D motors being increasingly difficult to source, VFD can be used to modify the torque curves of off the shelf motors. This allows for better speed control of mechanical presses. The ANSI Code requires all new control systems to have "Control reliability." This refers to the design and implementation of safety related control systems to consistently perform their intended safety functions, even in the presence of specific faults or failures. Key Aspects of Control Reliability: 1. Fault Tolerance: The system must detect and respond to faults (e.g., wiring issues, component failures) without losing its ability to protect operators or equipment. 2. Redundancy: Critical components are often duplicated so that the other can maintain the safety function if one fails. 3. Monitoring: The system must continuously monitor itself to detect failures and take the appropriate action (e.g., stopping a machine if a safety function can't be guaranteed). 4. Fail-Safe Operation: In the event of a failure, the system defaults to a safe state (e.g., shutting down machinery). For Example: In a machine with a safety gate, control reliability ensures that if a contactor fails or a wire breaks, the machine will still stop when the gate is opened, maintaining operator safety.

Hydraulics Significant advances have been made in hydraulic components and controls. While some components can be rebuilt, older components are phased out. While OE rebuilt components can restore a machine to its original operating standard, modern controls can enhance the performance of older equipment. OE hydraulic equipment is also engineered and sized to meet specific customer requirements. Hydraulic systems are designed to optimize performance and minimize heat and pressure spikes. Hydraulic schematics are documented to assist with machine function and system diagnostics. Modern hydraulics are also smarter, communicating with the control system to provide an active schematic on the operator’s screen, providing real time pressure, temperature and position feedback for easier diagnosis. Adjacent to hydraulics, OE lubrication systems are engineered per specific application. Lubrication systems are designed to apply only as much lubrication as needed, based on effective area, velocity, and load. Because the system is properly sized abrasive wear is reduced, and less lubrication is wasted. In one application oil (or grease) consumption was cut in half with no adverse effects to the equipment. When rebuilding, updating, or re-rating forging equipment in particular, OE support isn’t a luxury, it is a strategic advantage. With original specifications, updated technologies, and a deep understanding of the equipment, OE provides peace of mind and performance you can count on. Jared Green, Sales Application Engineer with Ajax/CECO/Erie Press.

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