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CSH Die Cushion Drive

In deep drawing presses, two subsystems play the decisive role for productivity and workpiece quality: the press drive and the die cushion. A precisely defined blank holder force ensures controlled flow of the material into the drawing die and is the basis for a stable forming process. The innovative Voith CSH Die Cushion Drive provides you with a highly flexible servo-hydraulic drive system. With this drive, you actively and precisely set the characteristics for position, force and speed – and you can do this over the entire deep drawing process. Your die cushion becomes a servo cushion!

Conventional die cushion drives and control systems usually incur losses. Often, these drives require cooling systems that consume additional energy. Even the energy that the motion of the ram introduces into the die cushion is almost always lost in the form of thermal energy (heat).

With the Voith CSH Die Cushion Drive, this is completely different: The servo technology is innately economical in energy consumption. In addition, it is possible to recover virtually all of the energy of the ram motion in the form of electrical energy. As a result, you considerably increase the energy efficiency of your press. You save up to 80% of the energy costs compared to a conventional hydraulic die cushion drive without servo technology.

The CSH Die Cushion Drive represents a unique solution both for the modernization of existing presses and for new systems. Customarily, productivity can be increased by 50% and more. You can fabricate complicated deep-drawn parts economically with a reliable process. The press produces at a remarkably lower cost/piece. This enhances the competitive position.

Contact

Voith Turbo H + L Hydraulic GmbH & Co. KG
Schuckertstr. 15
71277 Rutesheim, Germany

Tel. +49 7152 992-3
Fax +49 7152 992-400
sales-rut@voith.com

Technical Data

Blank holder force, die cushion force 100 to >10.000 kN
(10 to >1,000 t)
Rated power up to 2 MW
Position-control accuracy up to 0.01 mm
Force-control accuracy up to ± 1%
HMI 15.4-inch TFT LCD control panel with intuitive touchscreen operator interface.
Communication PROFIBUS/PROFIsafe, PROFINET, Ethernet, USB


Are you looking for a die cushion drive with different data? We are sure to have a solution for that one as well.

Typical Applications

  • Retrofit of hydraulic die cushion drives and control systems
  • Upgrade of mechanical, gas spring supported or hydraulic blank holders
  • Retrofit of servo-electric die cushion drives
  • Deep drawing presses:
    – Hydraulic presses with die
    cushion
    – Servo presses with die
    cushion
    – Mechanical presses with die
    cushion
  • Perfect complement to the Voith PSH Servo Press Drive
  • Defined delay of high-mass bodies

Advantages and Benefits

_

Features Advantages Benefits
  • Actively controlled servo pump with a servo motor that operates as a motor or generator.
  • No classic valve and control technology.
  • Even the energy that the motion of the ram introduces into the die cushion can be recovered in the form of electrical energy.
  • The energy efficiency of the die cushion drive is exceptionally high.
  • You save up to 80% of the energy costs compared to a conventional hydraulic die cushion drive.
  • The press produces with a low cost/piece; you enhance your position over that of your competitors.
  • Control modes provided by the servo pump:
    – Position (selectable)
    – Speed over stroke
    – Force over stroke
  • Design freedom for the entire deep drawing process with regard to the characteristics for position, speed and force (servo cushion!).
  • The adjustable blank holder force allows arbitrary characteristics for the surface pressure – even decreasing or oscillating ones.
  • Deep drawn parts can be fabricated with a reliable process.
  • With a reliable, repeatable deep drawing process, you increase the productivity of the press by up to 50% – even more in individual cases.
  • A controlled, reproducible die cushion force characteristic results in a defined material flow and avoids significant creases and cracks in the workpiece.
  • Complicated deep drawn parts can be fabricated economically and with the fewest rejects.
  • The drawing depths of workpieces can be expanded considerably.
 
  • Pre-acceleration of the die cushion can be selected as desired (synchronization).
  • The impact caused by the top die con­tacting the workpiece is minimal. The quality of the parts produced improves due to the reduced damage to the surface.
  • The dies and the press itself experience a reduced load and have longer service lives. This reduces your operating costs significantly.
  • Noise emissions lowered up to 8 dB(A) reduce the effort and the costs for noise abatement.
 
  • Decoupling the motion of the die cushion from the ram motion is easily possible after reaching bottom dead center.
  • The die cushion with the workpiece can be moved independent of the ram.
  • Following the draw process, no counter forces from the die cushion act on the ram. Reduced loading increases the lifetime of the die and the press.
 
  • A part ejection function can be programmed.
  • Your deep drawing press produces large and complicated workpieces without damage.
  • Modular, simple design.
  • Few components.
  • Small oil tank.
  • This keeps the planning effort associated with system integration low.
  • The drive can be scaled for virtually all deep drawing presses.
  • Short development times save you planning costs.
  • The drive is ideal both for new presses and for modernizing or retrofitting.
 
  • The die cushion drive has a simple design.
  • The drive is operationally reliable and has high availability.
  • Low maintenance and repair costs.
 
  • The oil volume in the system is up to 80% less than for a conventional hydraulic die cushion drive.
  • The small effort for oil management has a positive effect on operating costs.
  • (Servo) hydraulic solution.
  • The drive has safe, fast-acting overload protection.
  • You avoid significant damage to the press in the event of incorrect operation or a malfunction.
  • Restarting is quick.
 
  • The number of wear parts is low; they have a high lifetime, are inexpensive and easy to replace.
  • The die cushion drive has long main­tenance intervals and short maintenance times.
  • The availability of the press increases.
  • The drive can be programmed via a 15.4-inch TFT LCD control panel with intuitive touchscreen operator interface.
  • The drive has a high degree of flexibility and is suitable for all die cushion applications.
  • The control system is pre-engineered with standard software.
  • You can integrate the drive into the press fast, easily and economically.
  • This keeps startup effort and costs low.
 
  • The HMI interface is convenient and modern.
  • All relevant parameters can be programmed and visualized on site.
  • The initial training of your operating per­sonnel is short.
  • Fast, informative process visualization and monitoring is possible on site.
  • Integrated process monitoring.
  • The drive system has its own diagnostics and is Industry 4.0 ready.
  • Maintenance needs can be detected early and extremely quickly.
  • Downtime of the press is considerably less.
  • On-site service calls can be reduced by up to 70%.
  • Control algorithms are perfectly adapted to the hydraulics and electronics.
  • The die cushion drive is a complete, single-source solution.
  • Shorter development and startup times save you money.

Technical Information

Stand-alone solution

CSH Die Cushion Drive as a stand-alone solution

Schematic diagram

Combination with the PSH Press Drive

CSH Die Cushion Drive in combination with the PSH Press Drive – the best drive solution for servo presses

Schematic diagram

Comparison of die cushion systems

Comparison of die cushion systems

During the deep drawing process using single-acting presses, die cushions are an extremely important component for the productivity of the press and the quality of the workpieces. For controlling die cushions, various systems of differing complexity and functionality have become more or less popular on the market. The Voith die cushion drive, however, is the only system offering such wide functionality combined with minimal complexity.

The following table shows different systems and their disadvantages compared to the Voith CSH solution:

Other cushion systems Disadvantages
Double-acting hydraulic cylinder using classic hydraulic drive system and valves
  • Cooling system and cooling power necessary
  • Average or poor reproducibility
  • Low efficiency
  • Complicated and failure-prone solution
  • Energy recovery not possible
Die cushion shafts with high-pressure/low-pressure switch and partial energy recovery
  • Average or poor reproducibility
  • Average efficiency
  • Complicated and failure-prone solution
  • Average control characteristics with lower accuracy and dynamic behavior
  • Limited energy recovery
Servo-electric (electromechanical) die cushion drive
  • Difficult to control overload situations
  • Fatigue critical solution
  • Very sensitive to maintenance errors
  • Limited dynamic behavior
Single-acting hydraulic cylinder with classic valves
  • Average or poor reproducibility
  • Pre-acceleration not possible
  • Cooling system and cooling power necessary
  • Low efficiency
  • Energy recovery not possible
Die cushion with gas springs
  • Pre-acceleration not possible
  • Almost impossible to affect force characteristic over drawing distance
  • A blank holder force that is constant or increasing over drawing distance only causes increasing surface pressure
  • Not possible to decouple from the ram movement
  • Low efficiency
  • Very high maintenance costs
  • Energy recovery not possible
  • Difficult to control overload situations
Die cushion with mechanical springs
  • Pre-acceleration not possible
  • Impossible to affect force characteristic over drawing distance
  • A blank holder force that is increasing over drawing distance only causes a greatly increasing surface pressure
  • Not possible to decouple from the ram movement
  • Difficult to control overload situations
  • Low efficiency
  • Energy recovery not possible

Publications

  • Saving Energy while Increasing Productivity. Servo-Hydraulic Drive CSH for Die Cushion

    Download
  • Transforming Your Press into a Servo Press. Press Drive PSH

    Download

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