Power density is a common topic for ARKU, especially when discussing the best-possible sheet metal fabrication procedures. This refers to applying the greatest degree of deformation to the sheet metal part in the smallest space possible [and then eliminating these deformations through targeted alternating bends to achieve complete flatness]. That is why precision levelers are designed with an extremely rigid machine frame, small leveling rollers with a minimal roller gap, solid backup bearings and powerful drives. High performance is key when it comes to leveling. The more force the machine can apply to the sheet metal, the more effective the leveling. The parts therefore have less internal stress and are level. To further improve efficiency, ARKU utilizes powerful servo-hydraulics in the FlatMaster® series.
These four hydraulic cylinders are responsible for the positioning of the leveling rollers and keeping leveling gap constant. This ensures especially high-quality leveling results for punched, laser, plasma, and flame-cut parts. In addition, this hydraulic system also protects the leveler against overloading. The FlatMaster® is the first choice when working with thicker parts – where powerful machines and good leveling results are essential. The exceptionally durable hydraulics are designed to handle extreme forces, making them highly effective in a leveler.
When it comes to energy efficiency, ARKU makes no compromises with the successful design of the FlatMaster®. State-of-the-art overload protection and top leveling results together with an unmatched processing spectrum are all integral parts of the hydraulics and the FlatMaster® name.
When it comes to energy efficiency, ARKU makes no compromises with the successful design of the FlatMaster®. State-of-the-art overload protection and top leveling results together with an unmatched processing spectrum are all integral parts of the hydraulics and the FlatMaster® name.
A long tradition in leveling
The very first generation of the FlatMaster® precision leveler was far superior to existing solutions in terms of energy consumption. From the start, ARKU has relied on a mix of electric drives for the leveling rollers and servo-hydraulics for the machine control in order to reliably protect the machine against damage due to overload. The combination of electrical and hydraulic systems significantly reduced energy consumption. Especially in comparison to the conventional fully hydraulic machines of the time that also utilized hydraulic energy for the leveling rollers.
Even several hundred machines later, ARKU is certain that this is the right combination. ARKU’s engineers have continued improving the energy efficiency of the machines, also because customers have become more conscious in regards to sustainability and efficiency.
Fulfilling both international and company-specific environmental standards and audits is also essential. The hydraulic component manufacturers have also followed this trend. Today, ARKU utilizes state-of-the-art control and storage technology within the hydraulic machines.
“We are keeping a close eye on the developing trends in the mechanical engineering industry”, says Ewald Hund, Technical Manager at ARKU. “Currently, there is no effective alternative to hydraulics when it comes to providing the same speed, power and reliability. Over the years, we have optimized the hydraulics in the leveler to such an extent that we have achieved a standard, which is almost impossible to improve.” Effectively, the electricity costs play an almost negligible role given the hourly rates of the FlatMaster®.
The power-controlled hydraulics also provide the FlatMaster® with the necessary performance reserves precisely when they are needed. This briefly increases the electricity consumption – an intentional design aspect to achieve faster results during the first leveling run. This saves 50% power overall, even if the machine briefly draws an additional 5 kW at peak capacity.
In addition to optimizing the hardware, examining the leveling process in detail, in particular together with the customer is also a key aspect for enhancing energy efficiency. Leveling still often involves downtimes during loading and unloading or when inspecting the leveling results. “Today, our consulting focuses far more on the customer’s overall process and avoiding standstills than it did in the past. The topic of energy consumption has also become more relevant than ever before,” explains Peter Eiswirt, Business Area Manager at ARKU. “An effective chain of machines, the right handling equipment or automation before/after the leveler, all help to eliminate unnecessary standstills.” When longer waiting times occasional occur, automatic shutdown ensures that the machine switches into standby mode and consumes almost no electricity.
The touchscreen HMI is another valuable asset. It suggests optimum settings to quickly achieve the desired leveling results. By displaying reference charts, the machine can assist in finding settings which require less force or energy. Transparent energy consumption on its own, often helps customers to reduce wasted energy. Now customers can monitor the energy consumption in real time via the touchscreen HMI. Experience gained in the ARKU Leveling and Deburring Center and from customer analyses shows that, on average, only 10% to 20% of the maximum available machine performance is required.
By way of comparison: a modern leveler now consumes only a fraction of the energy of a laser or flame-cutting system.
