5 Types of Industrial Assembly Presses for Manufacturing ...

• Manufacturing facilities use industrial presses to create, form or assemble a product.
• 5 main types of presses are typically used in an industrial setting.
• Each type creates force in a different way that impacts the application, purchase price, operational cost, precision, and safety.

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Industrial presses apply a controlled force to a material or part to complete a process step. They can be powered by many different energy sources and range greatly in size. Many manufacturing facilities use an industrial pressing operation in their process to create, form or assemble a product.

Entire books are written on the topic of industrial press machines, so this article will narrow its focus and concentrate on the relatively low-force, precision press machines used to assemble component parts. Most assembly presses are made up of a frame, ram and platen. Custom press frame configurations give engineers endless options; however, most standard assembly presses utilize a &#;C&#; frame, &#;H&#; frame or two-post configuration. Regardless of the frame&#;s shape and orientation, the ram is the moving element that applies the press force, and the frame is a secure mount for the platen that holds the workpiece.

Types of Press Machines Used in Manufacturing Processes

Below, we&#;ve outlined the five main types of presses used in industrial settings, their typical usage, and methods that can be utilized to verify the assembly process. Each type of press creates force in a different manner and this impacts the application, purchase price, operational cost, precision, safety, and process feedback capabilities.

1. Manual Presses

As the name implies, these industrial press machines are powered by a human operator. They are simple, basic tools and therefore the purchase price and operational cost of this type of press is low. Manual presses utilize different methods to produce force and linear motion of the ram. A common press for very low-volume assembly work utilizes a self-contained hydraulic system. Pumped via a lever, a hydraulic cylinder slowly extends with high force to press self-guided assemblies together. This system is very slow and takes a lot of effort, so it is typically used only for one-off, high-force processes.

Arbor presses utilize a lever arm or large wheel with a mechanical linkage to move the press ram up and down. The force is amplified by the linkage, which is typically either a rack and pinion or toggle mechanism. Rack and pinion presses amplify the applied force equally throughout the entire ram stroke. Toggle mechanisms start out with a lower force and increase the amplification toward the end of the stroke. In all of these variants, the assembly process and speed is controlled entirely by the operator. Press monitoring options are limited but include stroke verification switches, force displays and also locking mechanisms, which prevent the ram from being raised unless the stroke has been fully completed. Like any hand tool, safe operation of the press is the responsibility of the operator.

2. Pneumatic Presses

These assembly processing machines utilize compressed air as their power source. A standard air cylinder and &#;two-hand, anti-tie down&#; control valves are used to initiate the press cycle and move the ram up and down in a safe manner. The maximum force is relatively low and is determined by the cylinder bore size and the pressure of the regulated air source. The press force is consistent throughout the entire ram stroke and cannot be adjusted mid-stroke by the operator.

Advantages of the pneumatic press type are its higher speed, relatively low total cost and reduced operator fatigue. However, the operator cannot &#;feel&#; the assembly process as there is no tactile feedback. With additional control devices and cost, the assembly process can be monitored using stroke position switches, linear transducers, load cells, and part sensing devices. Since air is compressible, unless an additional oil-dampening circuit is employed, the working press stroke may be choppy and vary from part to part. This inconsistency limits the resolution of the process monitoring system; therefore, pneumatic presses are generally not a good choice if precise force/distance signature analysis is a quality requirement.

If the operator has additional tasks, and two-hand controls limit throughput, a light curtain can be utilized as a component of the machine&#;s safety system. A machine safety assessment, by qualified professionals, is extremely important and should not be overlooked. Not only is compressed air stored energy, if the air source fails, the press ram could fall, which could also cause injury. To prevent a falling load, air-piloted check valves or shaft-locking devices may also be necessary.

3. Pneumatic Intensified (Air/Oil) Press

These machines are similar to pneumatic presses and many of the characteristics, advantages, disadvantages, and safety concerns mentioned above hold true. They are powered by compressed air; however, the addition of hydraulic oil into the control circuit enhances the capabilities of this press type. Since oil is not compressible, it can be safely intensified to high pressures. The high-pressure oil is smaller in volume than the air that produced it, so the total displacement of the high force stroke is relatively short.

This &#;power stroke&#; can, however, be controlled with flow-restricting valves resulting in a smooth, uniform ram motion. Packaged air/oil cylinders often advance the majority of their stroke with low force, and, after contacting the workpiece, they utilize internal fluid passages to automatically shift over to their full-force power stroke.

If the process requires force/distance monitoring or high force over a short distance, an air/oil press may be the best solution. These presses can consume a lot of compressed air, which is a costly form of energy; however, they can be a good, lower-cost solution in many applications.

4. Hydraulic Assembly Presses

This type of industrial machine utilizes plant electricity, a hydraulic power unit and a hydraulic cylinder to move the press ram. These presses can be purchased in a variety of pressures and a range of sizes as &#;stand alone&#; pre-engineered units. They are ready for use as soon as part-specific tooling is mounted to the ram and platen.

Like the pneumatic press, maximum force is determined by the machine&#;s cylinder bore size and regulated operating pressures. Unlike an air/oil press, the press force is consistent throughout the entire stroke range. Ram speed is limited by the flow and oil volume restrictions of the hydraulic power package and circuit. Operator safety is again a serious concern, and one must be sure to engineer the system utilizing applicable safety-rated switches and sensing devices.

With additional control devices and cost, the assembly process can be monitored using stroke position switches, linear transducers, load cells, and part sensing devices. Since hydraulic oil is not compressible, the entire press stroke will be a smooth motion, which enhances the resolution of the process monitoring system. There are many advantages to this type of press and many are used in factories around the world. The main disadvantages are the inevitable leaks, noise, smell and significant heat generated by the hydraulic power unit. In addition to the higher initial cost, maintenance costs can also be higher due to the system complexity.

5. Servo Electric Presses

These industrial processing machines have been around for decades and are continuing to grow in popularity. They are increasingly selected over the other press types in many factories as the cost of servo motors and control electronics has come down significantly in recent years. The initial higher investment is also offset by lower operational and maintenance costs of an all electro-mechanical system.

This type of press utilizes plant electricity, a servo motor/drive unit, and an integrated ball screw actuator to impart linear motion to the press ram. These presses can also be purchased as pre-engineered packages with a wide variety of options. It&#;s very common to have integrated load cells, linear transducers, external part sensing, and other quality monitoring devices controlling the process, thereby lowering scrap rates and improving quality significantly.

The press software generally offers options to assist with the controls integration of safety devices, HMI display screens, and statistical quality control packages. Another capability, offered by some servo press manufacturers, allows the addition of controlled rotational motion integrated with the linear motion. This is beneficial when the assembly procedure requires the components to be rotated relative to one another during the press stroke to prevent damage.

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What is a hydraulic press?

A hydraulic press is a powerful machine that utilizes hydraulic pressure to generate a compressive force. It consists of a hydraulic cylinder, which houses a piston, and a hydraulic pump that applies pressure to the cylinder. This force is then transmitted through a fluid to a ram, which exerts pressure on the material being worked upon. Hydraulic presses are widely used in various industries due to their ability to exert immense force with precision.

Types of Hydraulic Press

There are several types of hydraulic presses available, each designed for specific applications. Let&#;s explore some of the common types:

Vertical H Frame Press

The vertical H frame press is a versatile hydraulic press known for its robust construction and stability. It features a vertically oriented frame in the shape of an &#;H,&#; which provides excellent support and rigidity during operations. This type of press is often used for tasks such as bending, straightening, punching, and pressing operations.

Tyre Press

Tyre presses are hydraulic presses specifically designed for the assembly and disassembly of tires. These presses exert substantial force to mount and demount tires from rims efficiently. They play a crucial role in the automotive and tire manufacturing industries, ensuring safe and reliable tire installation.

C Frame Press

C frame presses, also known as gap frame presses, are characterized by their C-shaped frame structure. They offer open access from three sides, allowing easy loading and unloading of workpieces. C frame presses are commonly used for applications such as stamping, punching, and forming operations, providing flexibility and versatility in manufacturing processes.

King Pin Press

A king pin press is a specialized hydraulic press used in the heavy-duty automotive industry. It is primarily employed for the removal and installation of king pins in trucks, buses, and other large vehicles. This type of press enables precise and controlled force application, ensuring efficient king pin replacement and maintenance.

Dual Action Press

Dual action presses, also known as double-acting presses, are hydraulic presses that can exert force in both directions of the piston stroke. This feature allows for increased productivity and faster operation times. Dual action presses find applications in various industries, including metalworking, molding, and assembly processes.

What is a hydraulic press good for?

Hydraulic presses offer numerous advantages and find applications in various industries. Some notable benefits include:

• High force generation: Hydraulic presses can generate substantial force, making them suitable for tasks requiring significant pressure, such as metal forming, forging, and stamping.
• Precision and control: These presses offer precise force control, allowing for accurate and repeatable operations. This makes them ideal for applications that demand tight tolerances and high-quality outcomes.
• Versatility: Hydraulic presses can be adapted to perform a wide range of tasks through the use of different tooling and accessories. They can handle various materials and perform operations such as bending, straightening, shearing, and pressing.
• Safety: Hydraulic presses are equipped with safety features such as pressure relief valves, emergency stop buttons, and guards to ensure operator safety during operation. They also provide overload protection, preventing damage to the machine or workpiece.

What are the disadvantages of a hydraulic press?

Despite their many advantages, hydraulic presses do have some drawbacks. It&#;s essential to consider these factors when evaluating their suitability for specific applications. Here are some disadvantages of hydraulic presses:

• High initial cost: Hydraulic presses can be more expensive to purchase and install compared to other types of presses, primarily due to the complexity of their hydraulic systems and components.
• Maintenance requirements: Hydraulic systems require regular maintenance, including fluid checks, filter replacements, and seal inspections. Neglecting maintenance can lead to reduced performance, increased downtime, and potential damage to the press.
• Fluid leaks: Hydraulic presses rely on hydraulic fluid for operation, and there is a potential risk of fluid leaks. These leaks can not only result in environmental concerns but also lead to reduced efficiency and increased maintenance needs.
• Limited speed: While hydraulic presses excel in generating high force, they may have limitations in terms of speed compared to mechanical presses. The hydraulic system&#;s response time and the need to build up pressure can result in slower cycle times.

Is a hydraulic press better than a mechanical press?

The choice between a hydraulic press and a mechanical press depends on the specific requirements of the application. Both types have their advantages and considerations. While hydraulic presses excel in force generation and control, mechanical presses offer advantages such as higher speed and lower initial cost.

Hydraulic presses are often preferred when working with materials that require significant force, require precise control, or involve operations that demand flexibility. On the other hand, mechanical presses are suitable for applications where speed and efficiency are critical, such as high-volume production environments.

Ultimately, the selection of the appropriate press depends on factors such as the desired force, speed, accuracy, material characteristics, and budget constraints.

Conclusion

Hydraulic presses are powerful machines that find applications across various industries. Their ability to generate immense force with precision makes them valuable tools in metalworking, automotive, manufacturing, and other sectors. While they offer advantages such as high force capability, precision control, and versatility, it&#;s important to consider factors like initial cost, maintenance requirements, and speed limitations. By understanding the specific needs of an application, one can make an informed decision on whether a hydraulic press is the right choice.

FAQs (Frequently Asked Questions)

1. How much force can a hydraulic press generate? A hydraulic press can generate a wide range of forces, depending on the specific design and configuration. Some hydraulic presses can exert forces ranging from a few tons to thousands of tons.

2. Are hydraulic presses safe to operate? Hydraulic presses incorporate safety features and protocols to ensure operator safety. These include emergency stop buttons, pressure relief valves, and guards. However, proper training and adherence to safety guidelines are crucial for safe operation.

3. Can hydraulic presses handle different types of materials? Yes, hydraulic presses can handle various materials, including metals, plastics, rubber, and composites. The selection of appropriate tooling and accessories allows for customization based on the specific material being worked upon.

4. How often should hydraulic press maintenance be performed? Regular maintenance for hydraulic presses typically involves periodic checks and inspections. The frequency of maintenance depends on factors such as usage intensity, operating conditions, and manufacturer recommendations.

5. Where can I find more information about hydraulic press manufacturers and suppliers? For information about hydraulic press manufacturers and suppliers, it is advisable to refer to industry-specific directories, online marketplaces, or search engines. Additionally, trade shows and industry exhibitions can provide opportunities to connect with suppliers and gather detailed information about available options.

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