How to Save Money When Buying Servo Press Solutions

Compared with conventional hydraulic or mechanical presses, servo eccentric presses provide considerable advantages, such as increased productivity and higher product quality. Furthermore, they offer the user enormous additional flexibility.

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Consisting of both control and drive technology, the Baumüller system solution gives you the advantages of a servo press while at the same time providing an instantly usable and flexible solution for your machine. We support you with the engineering and will implement the drive, machine control and software for you, completely and entirely according to your wishes. Baumüller also offers optional long-term life cycle management for your presse that is individually tailored to your needs and those of your customers. On request, we will also support you with the installation and commissioning of your system anywhere in the world.

With its components and services, Baumüller offers the largest scope of solutions for servo press drive systems. As a drive and automation manufacturer, we have many years of experience in equipping servo presses and, as a full-range supplier, we are at your side from the planning through to commissioning and service.

Benefits of a servo press compared to a conventional hydraulic and mechanical press

Compared to conventional presses, servo presses are a superior solution in terms of productivity, product quality and flexibility. With high-performance direct drives and the compatible control unit, the processes of servo presses can be optimized with regard to cycle time, tool wear and tear, energy use and environmental compatibility.

Precisely tailored to our customers: From the motor through to the complete drive system

Baumüller offers the exact service you require - from individual motors and components to comprehensive drive systems with control technology. We always support your precise needs. Baumüller is a partner for machine manufacturers and a supplier of complete systems.

Whether refurbishment or modernization – Baumüller provides the perfect drive solution for your servo eccentric press.

Complete drive system solution – scalable technology from Baumüller

Our system solution includes the complete main drive system with high-torque motors, servo converters and system inverters, including control cabinet construction as well as the control technology with hardware and an extensive complete software package specially for servo presses. The drive unit is configured individually depending on the required power.

The drive system is linked to a higher-level control system via a predefined interface and is vendor-neutral.

Our DST2-series high-torque motors achieve very high maximum torques, in order to provide the necessary power for the forming process. The motors can be perfectly adapted to the press’s requirements thanks to different shaft and flange options. We also enable the press power to be divided between multiple motors connected via a master-slave coupling.

With the b maXX converter family, Baumüller offers suitable servo drives for high power classes. The servo drives impress with their compact installation dimensions and offer a broad and scalable selection of optional safety functions. The devices also have the option of energy recovery. The connected system load can be reduced by intelligent energy management and the use of capacitors as energy stores, which in turn saves energy and costs.

Everything from one source: A complete package, tailored to your needs

In order to provide the high press forces required for the servo eccentric presses, depending on the gear ratio, motors with very high maximum torques are needed. The Baumüller DST2 series high-torque motors are therefore predestined for this application. Due to their low inertia, they also meet the dynamic requirements of the application. 

Baumüller can also supply the right drive system for large servo presses. Thanks to the modular b maXX drive electronics, with the help of multiple-winding systems, even the large motors of the DST2 series with over 1,000 kW power can be used and combined to form multi-motor solutions.

The system is completed by the use of b maXX rectifier and regenerative feedback units and an energy store designed to precisely match the customer’s requirements.

Due to the modular use of components, this drive system kit enables us to realize a very wide range of presses with minimum variance in the drive system. This very much simplifies the order process as well as warehousing/replacement part stocks for the customer.

Standard control cabinets through to completely wired special control cabinet

Drive design with ProSimulation

The digital twin offers many advantages, especially during the engineering phase: The development time is shortened, and the machine can therefore be placed on the market as quickly as possible and functionally reliable. With ProSimulation, Baumüller offers simulation models of its drive components. In addition, Baumüller undertakes the complete design of the design technology for its drive technology.

This offers numerous advantages, particularly for complex applications such as servo eccentric presses: It enables the selection of an efficient and resource-saving drive package. For example, the whole drive topology can be mapped in the software. This consists of the nonlinear transfer ratio of the eccentric mechanics, gearing, high-torque motors, servo drive technology and energy store in conjunction with dynamic movement and force profiles. The simulation creates transparency in the power and energy profiles and describes charging and discharging processes in detail. This enables efficient dimensioning of the energy store and therefore the connected system load can be reduced. This saves resources, relieves the power supply system considerably and reduces the machine’s footprint.

Software solutions for servo presses

You save time and money with our complete software package, since all the basic functions of a servo press are available to you. They include, for example, the creation of movement profiles, energy management and a predefined interface with a higher-level process control. A standardized interface can be used to quickly and easily expand to include a customer-specific special function.

On the control level, Baumüller offers the powerful b maXX PCC-04 box PC, a scalable, versatilely usable platform which offers a large number of interfaces, is expandable, and therefore enables flexible machine architecture.

Our solution

Your path to a qualified quote

You would like a no-obligation consultation or quote? Then contact our experts.

We discuss the relevant technical details with you and together we define the requirements. Only then do we undertake the qualified design of the complete drive system. After checking the specifications, you receive a qualified quote from us.

Baumüller is your partner for the production-ready design and optimization of your drive system. As a non-group-affiliated, mid-sized company, we are able to respond to the wishes of your customers quickly and efficiently with innovative drive solutions. This makes us the perfect partner for challenging projects and future technologies.

Our components for servo presses:

1. Introduction to Assembly Presses

An assembly press is a versatile machine designed to apply controlled force to join, shape, or align components with precision. Commonly used in manufacturing, automotive, and aerospace industries, these machines streamline tasks like fitting bearings, pressing gears, or assembling electronic parts. Their ability to deliver consistent pressure ensures high-quality results, reducing errors compared to manual methods.

Assembly presses play a critical role in modern production lines. For instance, hydraulic assembly presses handle heavy-duty operations like forging metal parts, while pneumatic variants excel in high-speed, repetitive tasks such as electronics assembly. Custom assembly presses further cater to specialized needs, offering tailored solutions for unique material types or complex geometries.

Beyond industrial settings, these machines are vital in sectors requiring precision, such as medical device manufacturing or renewable energy systems. Advances in automation have also enhanced their efficiency, integrating sensors and programmable controls for smarter workflows.

Whether you’re working with delicate components or robust materials, understanding the basics of assembly presses helps in selecting the right equipment for your needs—a decision that directly impacts productivity, safety, and long-term cost savings.

2. Types of Assembly Presses

Assembly presses come in various designs, each tailored to specific tasks and industries. Understanding their differences ensures you select the right machine for your operational needs.

Hydraulic Assembly Presses

• How They Work: Use hydraulic cylinders to generate high, controlled force. Ideal for heavy-duty applications like forging metal parts or pressing large bearings.
• Key Advantage: Exceptional power and precision for demanding tasks.

Mechanical/Pneumatic Presses

• How They Work: Rely on mechanical linkages or compressed air for rapid, repetitive actions. Perfect for high-speed assembly of small components, such as electronics or automotive fasteners.
• Key Advantage: Speed and efficiency in mass production.

Custom Assembly Presses

• How They Work: Built to meet unique requirements, such as unusual part geometries or specialized materials.
• Key Advantage: Flexibility to adapt to niche industrial processes.

Industrial vs. Small-Scale Presses

• Industrial Presses: High-capacity machines for large-scale manufacturing (e.g., automotive frames).
• Small-Scale Presses: Compact units for workshops or prototyping, offering portability and ease of use.

Hydraulic models dominate heavy industries, while pneumatic systems thrive in precision-driven sectors. Custom solutions bridge gaps where standard presses fall short. By matching the press type to your workload, you optimize productivity and reduce operational costs.

3. Key Components and How Assembly Presses Work

Assembly presses rely on a combination of robust engineering and precise mechanics to deliver consistent results. Here’s a breakdown of their core components and operational workflow:

Core Components

• Frame: The sturdy base that supports the machine, often made of steel to withstand high pressure.
• Ram/Plunger: The moving part that applies force to the workpiece. Its speed and pressure are adjustable.
• Hydraulic/Pneumatic System: Generates power—hydraulic systems use fluid pressure, while pneumatic systems rely on compressed air.
• Control Panel: Houses buttons, levers, or digital interfaces to regulate force, speed, and cycle times.
• Die/Tooling: Custom attachments that shape or position components during pressing.

How They Operate

1. Workpiece Placement: The component is positioned on the bed or within the die.
2. Force Application: The ram descends, applying controlled pressure to assemble, shape, or compress the part.
3. Pressure Holding: Maintains force for a set duration to ensure proper bonding or forming.
4. Ram Retraction: The ram retracts, allowing safe removal of the finished workpiece.

Modern assembly presses often integrate automation, such as sensors to detect misalignments or programmable logic controllers (PLCs) for repeatable cycles. This reduces human error and boosts efficiency, especially in high-volume production.

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By understanding these components and processes, operators can maximize machine performance while ensuring safety and precision.

4. Benefits of Using Assembly Presses

Assembly presses transform industrial workflows by combining precision, power, and reliability. One of their standout advantages is enhanced accuracy. Unlike manual methods, these machines apply consistent force every cycle, eliminating human error in tasks like bearing installation or gear alignment. This precision is critical in industries like aerospace, where even minor deviations can compromise safety.

Increased productivity is another key benefit. Hydraulic and pneumatic presses automate repetitive tasks, slashing assembly times while maintaining uniform quality. For example, automotive manufacturers rely on them to meet high-volume production targets without sacrificing part integrity.

Cost-efficiency also plays a major role. While initial investments vary, assembly presses reduce long-term expenses by minimizing material waste and rework. Custom presses further optimize costs by tailoring operations to specific materials or geometries, avoiding the need for multiple machines.

Safety improvements cannot be overlooked. Modern presses feature guards, emergency stops, and automated sensors, reducing workplace injuries associated with manual force application. Additionally, programmable controls allow operators to manage processes remotely, further lowering risks.

From speeding up production lines to ensuring flawless component integration, assembly presses deliver measurable ROI across industries like medical device manufacturing, renewable energy, and electronics. Their adaptability to both heavy-duty and delicate tasks makes them indispensable in today’s competitive manufacturing landscape.

5. How to Choose the Right Assembly Press

Selecting the ideal assembly press requires aligning machine capabilities with your operational demands. Here’s a structured approach to simplify your decision:

Key Factors to Consider

• Load Capacity: Match the press’s maximum force (in tons or kN) to your heaviest tasks—hydraulic presses excel for high-force needs.
• Workspace Size: Ensure the bed dimensions accommodate your largest components.
• Material Type: Hard metals may demand hydraulic systems, while softer materials work with pneumatic presses.
• Cycle Speed: High-volume production favors mechanical/pneumatic models for rapid cycles.

When to Opt for a Custom Assembly Press

Custom solutions shine in scenarios like:

• Unique part geometries needing specialized tooling.
• Hybrid processes requiring integration with robotics or sensors.
• Compliance with strict industry standards (e.g., medical or aerospace).

Comparing Brands and Features

• Durability: Prioritize heavy-duty frames and corrosion-resistant materials.
• Automation: Look for programmable controls (PLCs) or IoT-enabled systems.
• Safety: Features like emergency stops, light curtains, or overload protection.
• Support: Choose suppliers offering training, maintenance, and spare parts.

Final Tips

• Assess future scalability—can the press adapt to growing production needs?
• Request demonstrations using your specific materials or components.
• Balance upfront costs with long-term ROI, factoring in energy efficiency and downtime reduction.

By methodically evaluating these aspects, you’ll invest in a press that boosts efficiency, ensures safety, and aligns with your industry’s unique challenges.

6. Maintenance and Safety Best Practices

Proper maintenance and safety protocols are critical to extending the lifespan of assembly presses and ensuring operator well-being. Start with routine inspections of key components like hydraulic hoses, seals, and electrical connections. Look for leaks, cracks, or unusual noises during operation—early detection prevents costly breakdowns. Lubrication is equally vital; moving parts such as rams and guide rails require regular greasing to minimize friction and wear.

For hydraulic systems, monitor fluid levels and quality. Contaminated or degraded oil can impair performance and damage pumps. Replace filters as recommended by the manufacturer to maintain optimal pressure. In pneumatic models, drain moisture from air compressors to prevent corrosion.

Safety begins with operator training. Ensure all personnel understand machine controls, emergency stop procedures, and proper use of protective gear like gloves and safety glasses. Install physical safeguards such as light curtains or interlocks to prevent accidental activation during maintenance. Always lock out the power supply before servicing the press.

Finally, maintain detailed records of inspections, repairs, and replacements. This not only aids in troubleshooting but also ensures compliance with industry safety standards. By prioritizing proactive care and strict safety measures, businesses reduce downtime, avoid accidents, and maximize the reliability of their assembly presses.

7. FAQs

Assembly presses are vital tools in manufacturing, but their technical nature often raises questions. Here are answers to some of the most common queries:

What industries rely heavily on assembly presses?

Industries like automotive, aerospace, and electronics use assembly presses extensively. For example, automotive plants employ hydraulic presses for gear assembly, while electronics manufacturers use pneumatic models for delicate circuit board components.

Can assembly presses handle fragile parts?

Yes. Modern presses, especially servo-driven or pneumatic types, offer precise force control, making them suitable for fragile items like medical devices or microelectronics. Custom tooling further protects sensitive components during pressing.

How does a hydraulic tool assembly press differ from standard models?

Hydraulic tool presses are designed for high-force, heavy-duty tasks like forging or stamping. They use fluid pressure to generate immense power, whereas standard mechanical presses rely on flywheels or pneumatics for lighter, faster operations.

Are custom assembly presses cost-effective?

While custom solutions have higher upfront costs, they often save money long-term by optimizing workflows, reducing waste, and eliminating the need for multiple machines. They’re ideal for niche applications with unique part geometries or materials.

What safety features should I prioritize?

Look for emergency stop buttons, light curtains, and overload protection. Regular training on lockout/tagout procedures and proper tooling setup also minimizes risks.

How often should maintenance be performed?

Follow the manufacturer’s schedule, but generally, inspect hydraulic fluid monthly, lubricate moving parts weekly, and check electrical systems quarterly. Immediate attention to leaks or unusual noises prevents major failures.

8. Conclusion

Assembly presses are indispensable in modern manufacturing, offering unmatched precision, efficiency, and adaptability across industries—from automotive assembly lines to delicate medical device production. Their versatility, whether through hydraulic power for heavy forging or pneumatic systems for rapid electronics assembly, ensures they meet diverse operational demands.

Choosing the right press hinges on understanding your workload, material requirements, and long-term goals. Equally critical is adhering to maintenance routines and safety protocols, which safeguard both equipment longevity and operator well-being. By investing in quality machines, embracing automation, and prioritizing training, businesses unlock higher productivity and ROI.

As technology evolves, assembly presses will continue to drive innovation, enabling smarter, faster, and safer production processes. Whether upgrading existing systems or integrating custom solutions, staying informed about advancements ensures your operations remain competitive in an ever-changing industrial landscape.

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