Highly integrated press safety and control block: A step towards efficiency and customer benefits
Efficiency and safety are the top priority in modern industry. To meet these requirements, the continuous optimization of machines and systems is essential. This applies to hydraulic presses, which are subject to performance level PLe in accordance with DIN ISO 13849-1 and are essential in numerous industries. A current example of such optimization is the introduction of a new press safety block with nominal size (NG) 16 - an innovation initiated by Wickert Hydraulic Presses that will replace the previous generation of blocks from June 2024.
Reasons for the introduction of the new press safety block
The components previously used in the standardized press controls are continuously evaluated to improve both functionality and cost-effectiveness. In particular, the following optimization options were identified:
- Saving a prop. throttle valve of the NG25:A proportional throttle valve of nominal size 25 (NG25), which is not required for certain applications, is integrated in the standard control unit used to date. This valve will no longer be installed in the future, which saves both the valve itself and the associated installation work.
- Replacement of the directional control valve: The previously installed block always required the replacement of a directional control valve with a proportional directional control valve and vice versa if an application required this. This is no longer necessary with the new solution, which eliminates the replacement process and reduces costs.
- Retrofitting a vacuum load-holding valve: With the previous control block, it was necessary to retrofit an additional vacuum load-holding valve. This subsequent adjustment is not necessary with the new block because the valve is integrated into the block from the outset. This reduces the complexity of the installation. This reduces the complexity of the installation.
- Extended retrofit options: The new block offers the flexibility to easily retrofit valves for special functions in the future, such as slow movements in creep speed. This allows the press to be adapted to specific requirements without great effort.
Goals of the optimization
The introduction of the new press safety block aims to maintain the performance of the press control system while enabling better customisation to specific requirements. The optimisations lead to several benefits:
- Reduction of assembly work:The simplification of the control block and the elimination of unnecessary components considerably reduce the installation effort..
- Minimisation of the error rate: Fewer components and fewer subsequent adjustments also mean less susceptibility to error and malfunctions.
- Reduction of control block diversity: Standardisation on the new block reduces the number of different control block types within the WKP S series, which optimises warehousing and procurement.
- Improvement of purchasing conditions: Reducing complexity and the number of variants results in better purchasing conditions, which ultimately also lowers the manufacturing costs of the presses.
Customer benefits through the optimisations
The technical improvements mentioned above have a direct impact on the benefits of Wickert Hydraulic Presses' customers and offer several benefits:
- Lower operating costs: The reduction in assembly activities and the elimination of unnecessary components reduce operating costs. This leads to improved profitability and enables more competitive pricing.
- Increased reliability and operating time: Fewer sources of error and a simplified design mean greater system reliability. Customers benefit from an extended operating time for their presses and reduced downtimes.
- Flexibility in adaptation: The ability to easily retrofit additional valves, such as for creep speed, allows customers to flexibly adapt their presses to specific requirements. This ensures that the machines can be used optimally even when production requirements change.
- Faster commissioning: By reducing the variety of control blocks and simplifying the assembly processes, the commissioning time of the presses is shortened. This enables customers to start production more quickly and thus reduce time-to-market.
- Simplification: Maintenance and fault analysis by the customer are simpler and can be carried out more easily by the maintenance department.
- Long-term security of investment: The improved standardization and simplification of the technology lead to increased availability of spare parts and a longer service life for the presses. This gives customers the security of knowing that their investment is protected in the long term.
Conclusion
The new press safety block with NG 16 is a decisive step towards more efficient, safer and more cost-effective production - an innovation initiated by Wickert Hydraulic Presses. The optimizations not only offer technical advantages, but also create clear added value for customers, who benefit from reduced costs, increased flexibility and a longer service life for their systems.
With this innovation, Wickert Hydraulic Presses is setting a clear example in the further development of future-proof and cost-efficient press technology and offers its customers solutions that more than meet the increasing demands of the industry.
