Progressive Presses

Although we have standard products in two connecting rod and four connecting rod configurations, we produce eccentric presses up to 1000 tons in a single connecting rod.
It is communicated over profinet with sheet feeding system.
In industrial standards, PLC, operator panel, cam case, clutch brake valve, clutch brake, encoder and light barriers are selected from globally accepted brands.
All of our presses are hydraulically fused and have regulation adjustment.
Our presses are PLC controlled. We use safety PLC or safety modules in accordance with 2006/42/EC regulation. Depending on the size of the press, we use 9” or 12” rotary console operator panels.
Prescription-based press speed adjustment and regulation adjustment can be made with the encoder from the operator panel.
We manufacture our presses with fixed or mobile plate and cushioning according to your request.
Our gears are zero-gap herringbone gears.

Body Structure

In progressive presses, mono-block body or tension shaft body can be preferred.
In both body structures, we design by considering the maximum deflection 0.12 mm/m.
The tonnage to be applied in each station of the progressive mould is a critical input in terms of body, ram and sled design.
We design the nuts in the tensioner shaft structure with hydraulic self-tensioning. It ensures that it can be disassembled by applying pressure without the need for additional equipment. It provides convenience for transportation and maintenance.
The side clearance between the columns is determined by the width of the roll to be fed. The position of the columns is one of the criteria determining the whole body structure.
Tonnage and table size determine the press pit requirement

Body design and Manufacturing

Body design is analyzed with Ansys finite element software. In the analysis, we maintain design improvements until we achieve an infinite fatigue life.
We report the results obtained and maintain them by documenting them.
The body is obtained by welding St52-3 quality plates. Welding is performed by certified welders using SG3 welding wire.
After welding, the body is placed in the furnace and subjected to stress relieving process.

Mechanism design

The high speed and reasonable course values required in progressive presses are often provided by the slider crank mechanism.
In our presses, we use an eccentric crank-connector system.
The eccentric system from the gear has superior strength and machine life compared to the direct crank mechanism.

Kinematics

During the process, the parameters of velocity, position, and acceleration are optimized within the limits allowed by the mechanism to properly direct the flow occurring in the material.
While aiming the most appropriate movement curve for the process, it is ensured that the forces to be applied to the press limbs and bearings are kept to a minimum.

Power Train Design

By using the results obtained from the mechanism design and kinematic data, the designs of the powertrain are carried out.

Analysis

In our designs, we use the finite element method to estimate how the powertrain behaves. We use ANSYS software for these analyzes we perform in the computer environment.
ANSYS, one of the modern simulation software, contains the finite element method on its basis. It helps us find the weakest point in our designs and make parameter optimization.

Slide Guiding

The ram is guided on the columns from 8 surfaces.
Each plate is precisely adjusted and secured by means of bolts in the x and y directions.
Optimized lubrication channel and precision machined bronze bearings work on steel plates.

Clutch & Brake

Pneumatic or hydraulic clutch type is used.
Depending on the press speed, mechanism and operating conditions, the clutch type is selected.
The required clutch and brake size are calculated according to the transmitted power, torque, tonnage and speed information.
Clutch- The brake is controlled by a double valve control system with monitoring, three-way safety. It is vitally important for occupational safety.

Shut Height Adjustment and Overload Protection

The ram table height adjustment is achieved by the movement of the nuts working on the thrust bolts.
In our presses, the shut height adjustment and overload protection systems are combined in a single body.
In case of a situation exceeding the press limits during any possible mould failure and mass production, the hydraulic overload valve is activated and possible damage is prevented.

Moving Bolster

One of the most important components of the transfer press is the mobile tables. The way to minimize mould fastening and setting time is to use double mobile table presses.
We manufacture electric motor, hydro motor or air motor driven mobile tables.
We place the mobile table lifting cylinders into the lower bridge. In the same way, we position the centering and locking assemblies in the lower bridge.
We also manufacture mobile tables with shaft holes in presses equipped with air-cushion.

2 Direction Moving Bolster

After the mobile table is out of the press, in some cases, the first movement direction must also move vertically.
We solve this need with 8-wheeled mobile tables. Press shop floor remains level again. 4 wheels to work for the second movement direction remain hidden inside in the first stage. When it comes to the direction change zone, it is activated and provides movement.

Opstion : Traveling Clamp

It is an SMED application used for automatic and fast connection of the upper mold to the press ram.
Preston mould retainers provide faster setup.
Each has a capacity of 6-8-10 tons and a 600 mm or 800 mm advance course.
Receives the plate presence/absence information and transmits it to the PLC.
Continuously checks the pressure, completes the missing pressure.
Transmits pressure incomplete status to the PLC as an emergency warning

Standart Progresif Pres Özellikleri

PresModelNumarası	PP300.2211.200	PP400.2512.250	PP500.2713.300	PP600.3015.400	PP800.3618.500	PP1000.4020.600	PP1250.4522.800	PP1500.5025.900
Tonaj	300 ton	400 ton	500 ton	600 ton	800 ton	1000 ton	1250 ton	1500 ton
Tabla ölçüleri	2250 x 1125 mm	2500 x 1250 mm	2750 x 1375 mm	3000 x 1500 mm	3600 x 1800 mm	4000 x 2000 mm	4500 x 2250 mm	5000 x 2500 mm
Kurs	200 mm	250 mm	300 mm	400 mm	500 mm	600 mm	800 mm	900 mm
Pres hızı	15-35 spm	15-35 spm	15-35 spm	15-35 spm	15-25 spm	15-25 spm	15-25 spm	15-25 spm
Maks. kalıp bağlama yüksekliği (SDAU)	650 mm	650 mm	700 mm	700 mm	800 mm	900 mm	1100 mm	1100 mm
Reglaj	200 mm	200 mm	200 mm	250 mm	250 mm	250 mm	300 mm	300 mm
Biyel sayısı	2 adet	2 adet	2 adet	2 adet	4 adet	4 adet	4 adet	4 adet
Tonaj anma ölçüsü	4,5 mm	5 mm	5,5 mm	6 mm	7,2 mm	8 mm	9 mm	10 mm
Hidrolik sigorta (HOLP)	var	var	var	var	var	var	var	var
Mobil tabla	opsiyon	opsiyon	opsiyon	opsiyon	opsiyon	opsiyon	opsiyon	opsiyon
Kavrama fren	Desch / Ompi	Desch / Ompi	Desch / Ompi	Desch / Ompi	Desch / Ompi	Desch / Ompi	Desch / Ompi	Desch / Ompi

Standart Progresif Pres Ölçüleri

ProgresifPresler	PP300.2211.200	PP400.2512.250	PP500.2713.300	PP600.3015.400	PP800.3618.500	PP1000.4020.600	PP1250.4522.800	PP1500.5025.900
H	6750 mm	6750 mm	7500 mm	7900 mm	8450 mm	9000 mm	9870 mm	10200 mm
H1	6500 mm	6500 mm	7000 mm	7250 mm	7700 mm	8100 mm	8620 mm	8900 mm
H2	250 mm	250 mm	500 mm	650 mm	750 mm	900 mm	1250 mm	1300 mm
H3	900 mm	900 mm	1000 mm	1100 mm	1100 mm	1100 mm	1100 mm	1100 mm
W1	5200 mm	5450 mm	5700 mm	6450 mm	7600 mm	8300 mm	9400 mm	9400 mm
W2	4500 mm	4750 mm	5000 mm	5750 mm	6900 mm	7600 mm	8700 mm	8700 mm
D1	3100 mm	3200 mm	3300 mm	3650 mm	4200 mm	4900 mm	5400 mm	5700 mm
D2	2300 mm	2400 mm	2500 mm	2850 mm	3400 mm	4100 mm	4600 mm	4900 mm