ST Servo Series Punch Press Helps Automotive Parts Manufacturer Achieve Efficiency & Quality Dual Upgrade

1. Background of the Client’s Pain Points

• Low Processing Precision, High Defect Rate: The Client’s core product is a 1.8-2.5mm high-strength steel (AHSS) reinforcement plate, which requires a dimensional tolerance of ±0.015mm. The original mechanical punch press had a repeat positioning accuracy of ±0.01-0.02mm, and the slider parallelism deviation exceeded 0.02mm/300mm, resulting in frequent problems such as uneven edges, material warping, and hole position deviation of the stamped parts. The product defect rate remained at 0.7-0.9%, which not only increased material waste but also failed to meet the strict quality standards of automotive first-tier suppliers.
• Low Production Efficiency, Serious Bottlenecks: The original mechanical punch press had a fixed stamping speed (45-50 SPM), and the stroke and motion curve could not be adjusted according to the forming process. For the 24-station progressive die stamping of reinforcement plates, each part required multiple stamping operations due to the limited bed size and inflexible motion control, resulting in a daily output of only 9,000 pieces per machine. With the continuous increase of the Client’s orders, the production capacity gap reached 30%, and the delivery pressure was prominent.
• High Energy Consumption and Maintenance Costs: The 160-ton mechanical punch press had a main motor power of 15kW, with a unit energy consumption of 0.85kWh/hour during full-load operation; the annual maintenance cost of 4 machines was about 60,000 yuan, and the core components (crankshaft, copper sleeve) needed to be replaced every 18 months, which significantly increased the production cost. In addition, the mechanical punch press had a large noise (82-85dB), which failed to meet the workshop environmental protection standards.
• Poor Process Adaptability: With the upgrading of automotive lightweight technology, the Client began to use ultra-high-strength steel (yield strength ≥1000MPa) for production. The traditional mechanical punch press had a single motion curve, which could not achieve slow forming in the critical forming stage, leading to frequent material cracking and mold damage, and the mold life was only 100,000 pieces, which seriously affected the continuity of production.

2. Qiaosen ST Servo Series Punch Press Customized Solution

2.1 Core Equipment Selection and Configuration

• STC-200sv (2 sets): C-frame double crank structure, suitable for large-batch stamping of automotive structural parts; nominal pressure 200 tons, slider stroke 10-250mm (programmable), no-load SPM 20-120, full-load SPM 55-65. Equipped with 15.6-inch color touchscreen HMI, supporting multilingual operation and real-time data monitoring, which is suitable for the stamping of 1.8-2.5mm high-strength steel reinforcement plates.
• STD-250sv (1 set): H-frame single crank structure, with ultra-high rigidity; the fuselage deflection under 110% full load is ≤0.025mm/m, which is suitable for the stamping of 2.5-3.0mm thick high-strength steel chassis connectors, effectively suppressing fuselage deformation and ensuring stamping precision.

2.2 Key Technical Adaptations

• Servo Drive System Optimization: Adopting direct servo motor drive (no belt/pulley loss), with 9 built-in programmable motion curves (including pendulum curve, slow forming curve, etc.). For the stamping of ultra-high-strength steel, the slow forming curve is used to reduce the forming speed in the critical stage (from 65 SPM to 30-40 SPM), avoiding material cracking and improving forming quality, which is consistent with the application characteristics of servo presses in high-strength steel hot stamping.
• Precision Control Enhancement: The whole machine meets JIS Class 1 precision standard, with slider parallelism ≤0.015mm/300mm and repeat positioning accuracy ≤±0.003mm. Equipped with high-frequency hardened guide rails (HRC ≥45°) and 42CrMo forged crankshaft, the motion pair gap is controlled within 0.005mm, ensuring long-term stamping precision stability, which is better than the precision level of traditional mechanical punch presses.
• Automation Matching: The punch press is connected with the Client’s existing servo feeder and six-axis robotic transfer system, realizing automatic feeding, stamping, and blanking, reducing manual operation, and avoiding human error. At the same time, the electronic cam and soft limit functions are added to avoid overload collision and mold damage, which is similar to the automation transformation scheme of servo punch presses in automotive parts factories.
• Energy-Saving and Noise Reduction Design: Equipped with brake energy feedback system, which can convert the kinetic energy during deceleration into electrical energy and feed it back to the power grid; the unit energy consumption of STC-200sv is only 0.72kWh/hour, and the full-load operation noise is ≤72dB, meeting the workshop environmental protection standards. In addition, the full-closed hydraulic lubrication system is adopted to extend the service life of core components.
• Mold Protection and Memory Function: Built-in 200 sets of mold memory functions, which can store the parameters of different molds, and the mold change time is shortened by 50% compared with the original mechanical punch press. At the same time, the current monitoring function is added to real-time judge mold abnormalities, reducing mold maintenance frequency and extending mold life, referring to the mold protection mechanism of servo punch press transformation cases.

2.3 Post-Sales and Technical Support

3. Application Effect and Data Comparison