Modernizing Hydraulic Systems for Enhanced Machining Center Performance

Modernizing Hydraulic Systems for Enhanced Machining Center Performance

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Challenges with Traditional Hydraulic Systems in Machining Centers

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Hydraulic powerpack systems are essential in machining centers (MC) for applications such as tool magazine tool change, spindle braking, and hydraulic workholding (fixtures). However, conventional hydraulic units present several challenges:

• Instant High Flow Demand: Operations like tool changes and workholding require immediate, high hydraulic flow. Traditional systems often respond slowly, which can reduce machining efficiency.
• Hydraulic Stability and Machining Accuracy: Significant pressure drops can weaken workholding force, negatively impacting machining accuracy and surface quality.
• Space and Maintenance: Traditional systems require large oil tanks and additional cooling units to prevent overheating. This increases the machine’s footprint, hydraulic oil consumption, and maintenance costs.

Advantages of ANYPOWER Servo Hydraulic Systems

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Switching to ANYPOWER’s servo hydraulic system addresses these issues with:

• Ultra-fast response (0.01s)
• Minimized pressure drop for enhanced machining accuracy and surface finish
• No need for additional cooling systems, reducing both cost and energy consumption
• Compact oil tank design, lowering machine footprint, CO₂ emissions, and oil usage during changes

Real-World Application Cases

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Case Study: Horizontal Machining Center (H Company)

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• Test Machine: Horizontal Machining Center
• Upgrade: Installed ANYPOWER servo hydraulic units
• Results:
  • Oil tank size reduced from 151L to 60L
  • Motor size reduced from 7.5HP to 5HP
  • Measured decreases in temperature rise, vibration (from 8.5μ to 3.8μ), and current values
  • No maintenance required since installation
  • Reduced oil tank size leads to lighter weight and lower carbon emissions
  • Zero maintenance equals zero service costs

Case Study: Gantry Machining Center (X Company)

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• Test Machine: Gantry Machining Center
• Upgrade: Replaced VANE-type hydraulic unit with ANYPOWER servo hydraulic unit (no other changes)
• Results:
  • Oil tank size reduced from 130L to 60L
  • Motor capacity reduced from 5.5kW to 3.7kW (approx. 7.4HP to 5HP)
  • Power consumption decreased from 1.39kW/hr to 0.32kW/hr (77% energy savings)
  • Significant reductions in temperature rise, vibration (from 4.0μ to 3.0μ), and current
  • 70L less oil used per oil change
  • No maintenance required since upgrade

Case Study: Air Compressor Manufacturing Plant (W Company)

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• First-time adoption of energy-saving hydraulic unit
• Results:
  • Tank size reduced from 20L to 15L
  • Motor reduced from 2HP to 1HP
  • Improved temperature rise, noise, and vibration
  • Over 25,000 hours of operation since 2019
  • Energy-saving efficiency reached 80%
  • Initial higher purchase cost recouped via electricity savings
  • Zero maintenance required

Case Study: Japanese Machine Replacement (P Company)

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• Upgrade: One of two machines originally equipped with traditional hydraulic units was replaced with ANYPOWER servo hydraulic units
• Results:
  • Tank size reduced from 20L to 15L
  • Motor reduced from 2HP to 1HP
  • Improved temperature rise, noise, and vibration
  • No maintenance required since 2019
  • Energy-saving efficiency reached 79%

Comparative Performance Tables

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Servo vs. Vane Pump Power Unit

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Servo vs. Piston Pump Power Unit

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Servo vs. Vane Pump Power Unit (P Company)

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Product Links

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Servo Hydraulic Power unit Piston Pump Power Unit Hydraulic Spare Parts