Speaker
Description
Over the past few years, Vecchiato has dedicated significant resources to researching and applying energy-saving technologies for Open Die Forging Presses. Building upon our patented HP3 flywheel system for hydraulic pumps, we have engineered and tested additional features to further optimize energy utilization.
This paper presents a case study of a recent upgrade, wherein a new 4’000-ton capacity press equipped with the advanced HP3 system was installed on existing foundations of a standard 2’500-ton press, previously operating with a fixed-speed motor and standard hydraulic features.
The newly integrated energy-efficiency features, entirely developed by the Vecchiato Engineering Team, includes: (i) Ecomodus speed management of the main pumps, which automatically reduces rotation speed during idle times; (ii) a servobalance system, an experimental device designed to recover the potential energy of the movable crosshead; (iii) variable speed drives for the piloting and filtration circuits; (iv) optimized hydraulic manifolds to minimize pressure drops.
This new installation enabled the Customer to achieve two primary objectives:
- Capacity upgrade without electrical overhaul: installing a significantly larger press without requiring additional electrical power infrastructure
- Enhanced energy efficiency: reducing energy consumption per ton of forged product by approximately 30% on similar product mix, as validated by empirical data gathered before and after the replacement.
By achieving these goals, the Customer successfully minimized both the CAPEX and the OPEX of the investment, leading to a substantial reduction in overall transformation costs.
| Speaker Company/University | Bertoldi Luca, Sales Director |
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