DV Hydraulics designed and built a fully customized press for sheet metal hydroforming.

This pre-stressed short-stroke press with a tailor-made hydraulic system was developed for extreme force, precision, and energy efficiency, with a focus on advanced control and maximum reliability. The press uses a servo pump system for highly efficient drive and is equipped with a Siemens S7-1518 PLC for precise and safe control.

Thanks to seamless integration into the complete production line, this press can produce a new sheet every 6 seconds, made possible by its continuous operation design.

Main Specifications of the Press:

• Pre-stressed frame: 16,000 tons

• Nominal pressing force: 12,800 tons

• Main cylinder: short stroke, rectangular: 800 x 800 x 15 mm

• Open/close cylinder: 300 x 260 x 150 mm

• Frame manufactured from forged components

• Total weight: 67 tons

• Fully in-house mechanical design and FEA simulation

• Precision-ground frame.

Main Specifications of the Hydraulic System:

• Nominal operating pressure: 2,000 bar

• Design pressure: 2,500 bar

• Pressure build-up speed: 1,000 bar/s or 6,400 tons/s

• Closed-loop speed control for fast opening and closing

• Precision force control with high-pressure measurement (0.1% accuracy, 10 kHz sampling)

• High-pressure medium: demineralized water

• Pilot system: hydraulic oil (250 bar)

• Energy-efficient drive system using servo pumps: 84% savings

  • Required power for conventional system: 90 kW

  • Actual consumption: 14.5 kW with Cos phi = 1

Control System Specifications:

• Proportional, custom-made high-pressure valves:

  • Operating pressure: 2,500 bar

  • Test pressure: 3,750 bar

  • Designed in-house

  • ATOS Axis controller as pilot valve.

• Siemens S7-1518 PLC and drives

This press combines extreme force, precision, and energy efficiency in one system.

Thanks to servo pump technology and a powerful Siemens PLC, this system is ideal for demanding industrial applications such as hydroforming.

At DV Hydraulics, we specialize in designing and building energy-efficient hydraulic presses that combine top performance with a minimal ecological footprint. Our innovative servo pumps deliver powerful, reliable, and energy-saving solutions – good for you and for the world of tomorrow. A servo pump system can be applied to many types of systems. Do you have an application where you want to save energy? Contact us!