Hidroliksan Press Machinery gains high precision and 50 % energy savings with their servo-controlled press machines.




Hidroliksan Press Machinery started in 1982 and is a Turkish based company, with a global reach with over 90 % export of their products. Customers are found in over 40 countries all over the world, primarily in Europe, USA, Middle East, West Africa and Asia, and their hydraulic press machines capable of performing up to 5000 tons per press, are primarily used within the automotive and automotive sub-industry, e.g. with customers amongst some of the most well-known car-manufacturers in Germany. 


Hidroliksan’s main mission is to create quality machines in line with European standards and CE norms with high precision and machines customized to the customer’s need. 

In their latest project, to modernize their machines with a servo-controlled press machine they were specifically looking for a partner that could supply:

Knowledge, experience and a quality solution for motion control  
An open universal software platform for application programming
The full automation system, including hardware and software
A price competitive solution

BoX2 pro motion for exact precision

Hidroliksan decided to go with the BoX2 pro motion from Beijer Electronics with extended technical support and implementation. The advanced setup was produced in collaboration with Beijer Electronics FAE’s. With the new motion and servo system, they have been able to increase the speed for pressing, and with the new control solution, a fully electrical driven system, it consumes 50 % less energy than the classic hydraulic systems. The machine runs more precise than the hydraulic system, in terms of position control and pressing power and can run from 1 kg to 20 000 kg per press at a time, while getting an exact precision and press tonnage control in every cycle of the pressing process. 

“With the new motion and servo system, Hidroliksan has been able to increase the speed for pressing, and with the new control solution, a fully electrical driven system, it consumes 50 % less energy than the classic hydraulic systems.”

Remote control and monitoring 

With the new servo system in place, the press machinery is being controlled and monitored remotely via a VNC application, and less periodic onsite maintenance is needed. The machine sends feedback on for example on the motor temperature, actual torque & velocity & position of the motor, energy consumption and more. 

Open hardware based on CODESYS programming 

An important requirement from Hidroliksan to modernize their machines, was the option for universal control software, future proof by being independent from one specific hardware manufacturer. The open hardware from Beijer Electronics which is based on CODESYS control, gives the customers the flexibility they need for updates, innovations and new features, that could easily be updated. 

“We first met with Beijer Electronics in 2015 regarding their HMIs. Since then, their solutions to our projects, the technical support and their approach have always been very satisfying. We chose Beijer Electronics in this new project as they could offer a complete solution. …” says Y. Emre Torun, Production Coordinator at Hidroliksan.  

Hardware and software supporting a flexible solution

Whether the customers are having an automatic workflow using robots to feed the presses, or operators handling the machines, any malfunction will send an alarm to stop the production. The new solution also included a barcode reader integration for reading barcodes on metal sheets with precise information about the weight, tonnage, etc. to be applied. Using iX developer software a recipe management system is introduced with a set of standard recipes which can be updated for new features and recipes when needed.

“We first met with Beijer Electronics in 2015 regarding their HMIs. Since then, their solutions to our projects, the technical support and their approach have always been very satisfying. We chose Beijer Electronics in this new project as they could offer a complete solution. Also, Beijer Electronics has shown to be a great partner for us as their products are IIOT ready by standard which means we can get crucial data from our machines for predictive maintenance” says Y. Emre Torun, Production Coordinator at Hidroliksan.

 

Open and flexible solution for future services

Hidroliksan is now looking to expand their services to customers by collecting data through Beijer Electronics CloudVPN and Cloud solutions. By getting access to the machine data the goal is to monitor the installed base for predictive maintenance and expand their customer offer with service agreements.

“…Also, Beijer Electronics has shown to be a great partner for us as their products are IIOT ready by standard which means we can get crucial data from our machines for predictive maintenance” says Y. Emre Torun, Production Coordinator at Hidroliksan. 

Learn more about the products in this solution:

Box2 pro motion
BSD 15KW Servo Set
Ethercat IOs
JetNet 2005 Switch
15” HMI
iX software
CODESYS  

 
 


 

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