KOMAGE GRE3N Line
KE Series:
The KE combines productivity and press technology flexibility with the advantages of electric drives
The machines of the KE Series are mechanical high-performance presses with a servo-electrically driven, freely programmable die axis. Komage has designed the presses of the KE Series specifically for manufacturing large quantities of molded parts from powder-based materials.
Due to the unique combination of mechanical top punch drive and servo-electric die drive, the user has a press system which combines the advantages of hybrid presses, i.e. the combination of productivity and press-technical flexibility, with the benefits of electric drives. As a result, the use of KE press systems can significantly reduce operating costs due to savings in energy consumption and maintenance.
With the launch of the electro-mechanical powder presses of the KE Series, Komage is continuing the consistent development of its range of low energy consumption presses.
Advantages of the KE Series
- High stroke rates (due to mechanically driven top punch movement)
- High spindle lifetime
- Low energy consumption (due to a combination of mechanical and servo-electric drive technology)
- Low environmental impact
Advantages of hybrid press systems
- High flexibility and parts quality, due to freely programmable die axis
- High reproducibility of the pressing process
- Pressing based on force or height
- Ability to implement all filling and pressing methods
- No mechanical fixed stops required due to freely programmable die movement
- Simple setup to shorten tool change times
- High product quality as neither knocks nor vibrations occur due to the lack of mechanical elements
- Instead of complicated mechanical adjustment, easy programming via software
- Optimum density distribution due to free programming of die movements
- Crack-free demolding due to freely programmable applied load
- Reduced tool wear due to freely switchable core rod
- Easy and error-preventing programming with the KOMPART integrated program generator
- Fast setup using an electronic handwheel (optional)
Advantages of servo-electric direct drives
- High energy efficiency
- Lower maintenance effort (no leaks, oil changes, etc.)
- Reduced space requirement
- Lower noise emission
- Outstanding positional accuracy due to direct drive
- High spindle life, no mechanical spindle offset required
- Sustainable drive concept (less energy, less noise, free from hydraulic oil)
Operating sequence
Filling techniques of the KE Series
The interplay between directly driven die movement and the mechanically or servo-electrically driven
filling system allows for different filling techniques:
- Fall filling
- Suction filling
- Falling suction filling
- Contour filling
- Underfilling
- Overfilling
- Hold times
- Shaking movements
Pressing processes of the KE Series
The machine's free programmability enables synchronously
accelerated or delayed movements of the die relative to the sinusoidal
motion profile of the top punch. The following pressing processes are therefore possible:
- Selectable pressing process using position or speed settings
- Two-sided pressing due to speed change of the die
- Shifting of the press neutral into any area by means of press stroke adjustment
- Optimized withdrawal
Due to the free programmability of the die, all filling techniques and press processes can be combined with each other and enabling optimal product quality as a result.
Control of the KE Series
The control system of the KE30 press has been specifically designed for high stroke rates while ensuring accurate axis positioning at the same time. As a result, the Komage KE30 press achieves a product quality which, with high productivity, meets the requirements of current and future quality systems and enables reproducible processes.
Features of the control system:
- Operator-friendly user interface in line with MS Windows
- Touchscreen
- Remote maintenance via the Internet
- No referencing of the axis necessary due to absolute measuring systems
- Electronic handwheel (scale graduation 0.01 mm), therefore easy setup of all axes
- Product quality of the highest level due to monitoring of all important parameters (forces, positions and lag)
- Monitoring functions for the protection of tool and machine
- SPC - quality control
- Automatic fill correction according to height or force
- Automatic correction within freely programmable limits
- Freely programmable switching points for all additional equipment
- (e.g., applied load, gripper, belt, etc.)
Komage KOMPART program generator
KOMPART gets you there faster:
- Fast and easy programming
- Programming with only 2 parameters: Part height and fill factor
- Integrated optimization functions
- Selection of different filling and pressing methods via touch screen
- Minimization of the setup time by automatically calculating all position setpoints