Hydraulic System for CNC Lathe
Optimizing CNC Machine Hydraulic Systems for Enhanced Efficiency
CNC machine hydraulic power packs utilize pressurized fluids to perform critical functions such as securely clamping workpieces via chucks and tailstocks, enabling rapid and precise turret tool changes, and providing reliable spindle braking. These integrated hydraulic operations enhance machining precision, operational efficiency, and overall safety.
Challenges of Traditional Hydraulic Systems in CNC Machine
- Hydraulic Pump Idling for Long Periods：
In CNC lathes, chucks and tailstocks do not require continuous hydraulic supply during machining. However, traditional hydraulic systems keep the pump running continuously, leading to unnecessary energy consumption. - Low Pressure Demand but High Sensitivity to Pressure Fluctuations：
During workholding and turret tool changing, a high-pressure surge is required instantly. Traditional hydraulic units struggle to respond quickly, causing pressure drops that negatively impact machining accuracy. - Overheating Issues：
Continuous operation of traditional hydraulic systems generates excessive heat, degrading the performance and stability of hydraulic oil, which affects machining precision.
Benefits of Switching to ANYPOWER Servo Hydraulic System：
- Pressure is supplied only when needed, eliminating unnecessary energy consumption during pressure holding.
- Fast response time (0.01s), minimizing pressure drops and improving machining accuracy.
- Prevents overheating from continuous operation, reducing the impact of high temperatures on machining precision and hydraulic oil stability.
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Application Cases
Background
- Automobile Transmission Shaft Processing Factory
- There are more than 120 CNC lathes in the factory.
- From 2019 to 2021, 15 Anypower servo hydraulic units have been replaced one after another.
Point
- All 15 units have been running for over 10,000 hours each.
- There are no maintenance records to date.
※ Although the initial purchase cost is higher than traditional options, the electricity bill has already been recouped.
※ Zero maintenance means zero service costs, saving company expenses.
These are actual measurement data from Company W. There are 15 servo hydraulic units
Testing Period:
From 1 pm March 1, 2018
To 11am Sep 6, 2018
Total operated 4088 hours
Total power consumption: 665.8 kwh (0.163 kwh per hour)
24 hours operation test (Mon to Sat)
Produce 1 component in 52 seconds.
Average producing 48 component in one hour
takes Servo hydraulic unit 0.16 kwh
and takes piston type hydraulic unit 0.68 kwh.
Conclusion: Servo hydraulic unit saves 76% energy than piston type hydraulic unit
Testing Period:
From 1 pm March 1, 2018
To 11am Sep 6, 2018
Total operated 4088 hours
Total power consumption: 665.8 kwh (0.163 kwh per hour)
24 hours operation test (Mon to Sat)
Produce 1 component in 52 seconds.
Average producing 48 component in one hour
takes Servo hydraulic unit 0.16 kwh
and takes piston type hydraulic unit 0.68 kwh.
Conclusion: Servo hydraulic unit saves 76% energy than piston type hydraulic unit
Background
- Company P purchased two machines from Japan's Company M.
- Both machines were originally equipped with traditional hydraulic units from Anypower. One of them was replaced with AnyPower servo hydraulic units.
Point
- The tank size was reduced from 20L to 15L.
- The motor was reduced from 2HP to 1HP.
- Improved temperature rise, noise levels, and vibration values were observed.
- Since the replacement with servo hydraulic units in 2019, there have been no maintenance records.
- Energy-saving efficiency reached 79%.
|
Item
|
AnyPower Servo Power Unit
|
Vane Pump Power Unit
|
| Power consumption per hour |
0.14kw-h
|
0.7kw-h |
|
Room Temperature |
29℃ | 28℃ |
|
Fluid Temperature |
30℃ | 39℃ |
| Rise of Temperature |
1℃
|
11℃ |
| Motor Temperature |
34℃ | 45℃ |
| Pump Temperature |
31℃ | 45℃ |
| Vibration |
1.3μ
|
3.5μ |
| SPL |
53db
|
70db |
| Current value R |
0.43A | 2.92A |
| Current value S |
0.20A | 2.55A |
| Current value T |
0.32A |
2.90A |
Servo hydraulic unit saves
79%
energy than vane type hydraulic unit
Servo Hydraulic Power unit
Piston Pump Power Unit
