Air consumption during working and idling of punch press

The gas consumption of punch in industrial production is affected by the working mode (working/idling), equipment parameters and process requirements. The following combination of theoretical calculations and actual data, for your detailed analysis:

1. theoretical calculation formula

punch gas consumption can be estimated by the following formula:

1. single air consumption of cylinder:

• d: Cylinder diameter (cm)
• s: Cylinder stroke (cm)
• p: Working pressure (MPa)

2. air consumption per hour:

• n: Number of work per hour
• 2.5: compressed air loss coefficient

2. actual working gas consumption

take JBS-50TS pneumatic punch as an example:

analysis of 3. Idling Gas Consumption

the main gas used during idling comes from:

1. pneumatic clutch clearance adjustment:
   • the large clearance causes the piston stroke to increase and the gas consumption to rise.
   • Normal clearance: 3mm; Abnormal case: 10mm (gas consumption increased to 3 times).
2. System pressure holding:
   • continuous air supply is required to maintain line pressure, but the flow rate is low.

Measured data: When a 200-ton punch is idling in a factory, the gas consumption is about 0.8-1.2m³/h, only 5%-10% of the working state.

4. key influencing factors

1. equipment parameters:
   • for every 10mm increase in cylinder diameter, the gas consumption increases by about 15%.
   • The stroke increased from 30mm to 50mm, and the air consumption increased by 60%.
2. Process requirements:
   • the stamping frequency increased from 30 times/min to 60 times/min, and the gas consumption doubled.
3. Maintenance status:
   • the seal ring is worn or the bearing clearance is too large, and the air leakage increases by 20%-50%.

5. energy saving optimization suggestions

1. equipment selection:
   • punch with gas tank is preferred to balance the fluctuation of gas consumption.
2. process optimization:
   • intermittent mode is enabled during discontinuous production to reduce idle gas consumption.
3. Maintenance Management:
   • check the cylinder seal every quarter and replace the worn parts.
   • Regularly calibrate the clutch clearance to reduce invalid travel.

Through reasonable selection, process optimization and maintenance management, the gas consumption of the punch can be reduced by 10%-25%, and the energy utilization rate can be improved.