Grundfos has taken a major technological leap with its new servo press from AP&T. The press combines extreme precision, user-friendliness, and optimal cybersecurity, while energy consumption per stroke has been reduced by up to 85 per cent.
Energy efficiency, high repeatability, and free programmability were among the principal requirements when Grundfos was looking to modernise a central part of its production of metal components for its pumps. The solution came through close collaboration with AP&T, resulting in the joint development of a world-first press system that is now in operation in Denmark.
– As far as we know, there is nothing like it anywhere else in the world. The press is fully programmable, can control the respective motor and pump for each cylinder and has amazing precision due to its ability to synchronize 4,000 times per second. We ourselves could hardly believe the numbers when we first looked at the metrics, says Peter Karlsson, Key Account and Area Sales Manager at AP&T.
Grundfos Project Manager Peter Lund Pedersen describes the initiative as an important strategic step in the company’s sustainability work.
– Our goal was to future-proof cold flow forming with a stable and energy-efficient solution. “We initially considered a control system overhaul, but when we saw the potential energy savings and process benefits of a brand new servo press from AP&T, the decision was easy,” he says.
50 years of combined experience in technological development
AP&T and Grundfos’ long-standing relationship has played a crucial role in the development. The collaboration began back in the 1970s and has led to several technical innovations – some of which are the only of their kind.
– Grundfos is a demanding customer – in the best possible way! Over the years, their needs have helped us develop solutions that have then found applications in other industries. Our collaboration has been a driving force in our technological development, to put it simply, says Peter Karlsson at AP&T.
Grundfos is also quick to emphasize the importance of mutual understanding.
– What makes our partnership so successful is the shared willingness to test new methods and our open dialogue. We maintain a good and open dialogue and have always had a strong consensus on the development of new production technologies, says Peter Lund Pedersen.
Energy savings visualized in real time
The new servo press is integrated into an automated line with two other machines from AP&T. All are connected to a visualization system that shows energy consumption in real time, both machine by machine and for the entire process.
– This new servo press consumes significantly less energy compared to the older machines. The new machine shows a clear 10-fold gain in efficiency over the old ones. “It makes it very clear that these are true energy savings on a large scale,” says Peter Karlsson at AP&T.
Grundfos itself has supplemented the line with an external screen that displays the energy data directly in production.
– Visualization has taken on an important function in our work. We use it to quickly detect deviations and drive improvements. It delivers a strong visual impact, especially compared to the older presses. We have an internal Green Team that actively works to identify energy savings, says Peter Lund Pedersen.
Programming freedom and nearly silent operation
Another key feature of the press is the freely programmable operator interface, where operators can control and adapt pressures, sequences, and cycles themselves, without the need for external programming.
– We have never seen such a flexible solution for cold flow forming anywhere in the world. It saves an enormous amount of time and boosts production capacity, says Peter Karlsson at AP&T.
– For our production, free programmability is crucial. It gives operators control, enabling prompt reaction to production changes, says Peter Lund Pedersen at Grundfos.
Noise emissions have also been reduced. At only 67 dBA during operation, the press contributes to a quieter and more comfortable working environment.
– Minimizing noise is always a goal when we invest in new equipment. The new press has brought a marked improvement to the working environment, says Peter Lund Pedersen.
Cybersecurity a business-critical factor
Cybersecurity has become increasingly important as digitalization expands. AP&T’s recent ISO 27001 certification has therefore been an important criterion for Grundfos.
– We require our suppliers to meet applicable security standards, especially when it comes to IT security. It’s a given today, says Peter Lund Pedersen.
Up and running, with high expectations met
The servo press is now in operation and the results of the first months live up to expectations in terms of both technical performance and energy efficiency.
– There is always a certain running-in period with new technology, but the machine is now up and running in stable production. The precision, noise level, and energy consumption are exactly as we hoped, says Peter Karlsson at AP&T.
And at Grundfos, clear results are already being seen, but Peter Lund Pedersen also emphasizes that the real effects will become apparent in the longer term.
– The most obvious result so far is the significant energy savings we see, especially in comparison to the previous press. We will only be able to assess other results once we have had the press in operation for a longer period. But even now, my clear opinion is that we have made the absolutely right decision – both in terms of choice of press and choice of AP&T as a supplier, he says.
