Energy-Saving All-Electric Rolling Machine Boasts Speed, Accuracy

March 20, 2024

The e-Power all-electric steel plate- and sheet-rolling machine, debuted in North America by Davi Inc. at FABTECH 2023, uses no hydraulic components, unlike existing hybrid concepts that blend hydraulics with electrics. This adaptation of electric power to all phases of rolling-machine operation reportedly improves ease of maintenance and energy efficiency, while delivering a quieter, compact machine that’s simple to install.

While a hydraulic rolling machine bends plates at speeds of about 20 ft./min., the e-Power processes material at 32 ft./min.—60% faster, according to company officials. Such processing speed significantly increases output, shortens turnaround times, improves productivity and maintains part quality. 

Davi-ePower-plate-rollA distinguishing benefit of an electric rolling machine, according to Davi Inc. officials: the ability to move multiple axes simultaneously. To maintain sufficient fluid pressure and flow, axis movement on a hydraulically driven machine is limited to two axes at a time, the officials explain. On an electric machine, separate motors are directly splined to the machine rollers and electrically controlled actuators can move as many as nine axes concurrently. Maximum speed and torque are available immediately no matter the number of axes in motion, without waiting for separate pairs of axes to complete their jobs. Smooth transitions between axis movements facilitate creation of complex bends.

In separate steps, a hydraulic rolling machine squares the material in the rollers, backs up the material, then raises the side rolls for a prebend operation. An electric machine, with its capability to move multiple axes simultaneously, brings the pinch roll up after squaring the material while at the same time performing prebending. The result: cycle times reportedly 40% faster than with hydraulic machines.

Regarding energy efficiency, the all-electric rolling machine consumes power only when actively moving machine components. With no movement, power consumption only is necessary to support the image on the machine’s computer control screen. Hydraulic machines, on the other hand, require continuous power to maintain fluid pressure even as no movement occurs, explain company officials. 

And, Davi’s all-electric machines have a start-and-stop feature similar to that on contemporary automobiles, utilizing energy only when required. Rolling processes routinely include idle times for part loading and other operations, and e-Power energy use on-demand supports energy conservation and contributes to sustainability and environmental responsibility. Overall, state Davi officials, all-electric rolling machines consume about 50% less power than hydraulic machines and approximately 30% less than hybrid electric/hydraulic units. And, as electric machines, they claim, can roll material 40% faster than hydraulic machines, total operating cost can decrease by 60%.

For increased accuracy, electric activation enables precision control of machine components. Standard positioning accuracy for a hydraulic machine is about 0.1 in. while electric machines reportedly provide accuracy of 0.05 in. (material thickness affects overall accuracy). And, the simplicity of electric-power delivery minimizes maintenance requirements as compared to hydraulics, given the possibilities of hydraulic-hose swelling and fluid leakage. An all-electric machine has no fluid hoses or connections to leak or clog.

The e-Power’s control allows operators to program the machine and automate rolling parameters that include speed, pressure and bending angles. The programs direct machine movements to occur smoothly and simultaneously to maximize efficiency and output. Customizing programs makes it possible to expedite specific jobs. 

Industry-Related Terms: Bending, Thickness, Torque
View Glossary of Metalforming Terms


See also: Davi Inc.

Technologies: Bending


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