High-speed press: analysis of core equipment for precision batch stamping

1. Core definition and structural composition
High-speed press is a type of stamping equipment with high-frequency reciprocating motion as the core, and converts motor power into high-speed linear motion of the slider through a precision transmission mechanism. It is mainly used for continuous precision stamping of thin materials (0.1-2.0mm), and can realize batch molding of motor cores, electronic connectors, automotive thin parts and other products. Its core structure is designed around "high speed and stability", with three major modules working together to ensure accuracy and reliability at high speeds.

1. High-speed transmission and drive unit

The power core uses a high-frequency response AC variable frequency motor or a high-speed servo motor, coupled with a precision crankshaft and toggle mechanism to achieve power transmission. Some high-end models adopt a double-crankshaft synchronous transmission design to offset the eccentric load torque generated by high-speed motion. The motor needs to have the ability to quickly start and stop and stabilize the speed. Through the cooperation of flywheel energy storage and clutch, it can ensure that the slider runs at a constant speed at a high beat of dozens to hundreds of times per minute. The transmission components are precision ground and dynamically balanced to avoid vibration during high-speed operation. Some models are equipped with an adaptive dynamic balancing system to compensate for motion deviations in real time.

2. Execution and carrying mechanism

The actuator is centered on a lightweight and high-strength slider, and is guided by eight-sided guide rails or rolling guide rails. The parallelism of the slider is controlled at ≤0.01mm/m to ensure no offset during high-speed movement. The slider stroke can be adjusted according to process requirements, and is usually suitable for short-stroke, high-frequency working conditions. The number of strokes ranges from 20 to 300 times/minute, and the micro electronic parts stamping model can reach more than 200 times/minute. The load-bearing frame adopts an integral casting or welded annealed structure, and its rigidity is more than 30% higher than that of ordinary presses. It can effectively absorb the impact force generated by high-speed stamping and suppress the vibration of the frame. It is also equipped with a forced lubrication and cooling system to reduce temperature and noise of high-speed running parts and extend service life.

3. Control system and auxiliary units

It adopts the "PLC + high-speed motion controller" architecture and uses a touch screen human-machine interface to achieve rapid parameter setting and real-time monitoring. The sampling frequency can reach 50kHz, and it can accurately capture the slider position, speed and punching force data. The core configuration is a mold protection system, vibration monitoring sensor and emergency braking device, which can respond to abnormal working conditions within 0.01 seconds to avoid mold damage or workpiece scrapping during high-speed stamping. Some smart models support quick mold change function, and the mold change time can be compressed to less than 3 minutes, adapting to the needs of mass production of multiple varieties. It also has automatic fault diagnosis and data statistics functions to assist production control.

2. Working principle and core advantages

1. Working principle

After the motor drives the flywheel to accelerate and store energy, the power is transmitted to the crankshaft through the clutch. The rotation of the crankshaft drives the connecting rod to drive the slider to perform high-speed reciprocating linear motion, completing the continuous cycle of "feeding-stamping-picking". The high-speed press adopts a motion mode of "high speed in idle stroke - stable speed in stamping section - high speed in return stroke". It optimizes the motion curve to reduce the impact of the start and stop of the slider. At the same time, the dynamic balance system and rigid frame are used to offset vibration to ensure stable stamping accuracy under high beats. Some models integrate servo control technology to achieve stepless adjustment of stroke speed, taking into account high-speed and flexible processing requirements.

2. Core technical advantages

Compared with traditional pressure equipment, high-speed presses have significant advantages in efficiency, precision and batch adaptability. The core highlights are as follows:

- Ultra-high production cycle time: The number of strokes is far higher than that of ordinary presses. Small and medium-sized models can reach 100-200 times/minute. Large-scale automotive parts stamping models can also achieve a stable cycle time of 10-15 times/minute. In the application of a new energy automobile factory, the average daily production capacity of a single high-speed press is increased by more than 50% compared with traditional equipment.

- High precision at high speed: Through precision guidance, dynamic balance correction and real-time monitoring technology, the stamping dimensional accuracy can be controlled at ±0.005mm, and the surface roughness is ≤Ra0.8μm, meeting the processing needs of precision parts such as motor cores and electronic connectors.

- Strong operational stability: The rigid frame and forced lubrication cooling system effectively suppress vibration and component losses, and the continuous operation without failure time can reach more than 800 hours. Ningbo Jingda’s high-speed production line can even achieve long-term continuous operation, adapting to large-scale mass production.

- Wide process adaptability: It can be adapted to a variety of thin materials such as cold-rolled steel plates, aluminum foil, copper foil, etc., and supports composite processes such as blanking, punching, bending, and deep drawing. By matching the automatic feeding and pick-up system, fully automated continuous production can be achieved.

3. Typical application scenarios

High-speed presses have deeply penetrated into the field of precision stamping of thin materials due to their high cycle time and high precision characteristics, and have become the core equipment for mass production in subdivided industries:

1. Automobile manufacturing industry

It is widely used in processes such as core stamping of new energy vehicle drive motors, molding of thin body parts, and processing of power battery structural parts. Changan Automobile's stamping workshop adopts a 5-sequence high-speed stamping production line, which operates stably at a beat of 10-15 times/minute. The high-speed production line for 46 large cylindrical battery structural parts developed by Ningbo Jingda has reached the industry-leading technology and has been equipped with leading car companies. International brands have advantages in the field of large-scale car body high-speed stamping lines, which can achieve efficient production of multiple types of car body parts.

2. Home appliances and electronics industry

Suitable for batch stamping of precision thin parts such as 3C electronic connectors, micro motor cores, and mobile phone parts. Such scenarios have extremely high requirements for rhythm and precision. The high-speed press can achieve stable stamping of more than 150 times per minute while ensuring part size consistency. In an application at an electronics factory, the connector defect rate can be controlled below 0.02%, greatly improving mass production efficiency.

3. Hardware and jewelry processing

Used for stamping processing of precision hardware accessories, thin parts of home appliances, coins/medal blanks and other products. With the advantage of high cycle time, it can achieve mass production of more than 100,000 pieces of hardware per day. At the same time, through precise pressure control, it can avoid defects such as wrinkles and cracks during thin material stamping, reduce raw material loss, and adapt to the large-scale production needs of the home appliance industry.

4. Precision machining

It is indispensable in the batch stamping of high-end products such as aerospace thin-walled parts and precision instrument casings. Such parts are made of special materials (such as aluminum alloy and titanium alloy thin materials) and have strict requirements on stamping accuracy and surface quality. High-speed presses can achieve precise forming of complex thin-walled parts through stable motion control and low-vibration design. Some high-end models also support multi-station collaborative stamping to improve processing efficiency.

4. Technical Parameters and Key Selection Points

High-speed press selection needs to focus on cycle time requirements, accuracy standards and industry adaptability. The core technical parameters and selection points are as follows: the number of strokes needs to be selected based on the type of workpiece. For electronic parts stamping, models with a speed of 100 times/min or above are preferred. For large automotive parts, 10-30 times can be used. /min model; the stamping accuracy must meet ±0.01mm and above, and the slider parallelism ≤0.01mm/m; the tonnage coverage needs to adapt to the material thickness and width. The 10-200 ton model can be used for thin material stamping, and the 200-500 ton model can be used for thick-walled and thin parts.

In addition, it is necessary to pay attention to the stability configuration of the equipment, and give priority to models with automatic dynamic balancing and forced lubrication and cooling systems; select mold change efficiency based on the production mode, and choose fast mold change models (mold change time ≤ 5 minutes) for multi-variety production; high-end industries such as automobiles and electronics need to choose models that support automated integration and can seamlessly connect with automatic feeding and pick-up systems; at the same time, evaluate energy consumption and maintenance costs, and give priority to low-noise, easy-to-maintain models to reduce long-term operating costs.