Insertion Machine Comparison: Electric vs. Hydraulic

How Does the PressOne Electric Insertion Machine Stand Up to Hydraulic Competitors?

When you’re choosing an insertion machine for your fastening needs, you will seek out the highest efficiency, accuracy, and speed. But you may not realize how the type of machine can determine these features.

Electric machines, like CoastOne’s PressOne Insertion Machine, differ from hydraulic machines in many important factors. In this article, we will compare the features of electric and hydraulic insertion machines to help you make an informed choice.

PressOne Insertion Machine Feeder

What’s an Insertion Machine?

Insertion Machines are devices that insert fasteners such as nuts, studs, rivets, or screws into various materials, creating strong and permanent joints. These machines are widely used in industries that require high precision, speed, and efficiency, such as sheet metal fabrication. Until recently, most insertion machines were run by hydraulic motors, but in the last few years, electric machines, such as CoastOne’s PressOne Machine, have made an impact on the market, offering features and benefits that were previously unavailable.

Electric Insertion Machines

Electric insertion machines use a servo motor-driven ball screw to generate force and move the ram that holds the punch. The ball screw is a mechanical device that converts rotational motion into linear motion with high accuracy and efficiency. Electric insertion machines have several benefits over hydraulic ones.

PressOne Insertion Machine Spindle
PressOne Insertion Machine Feeder
PressOne Insertion Machine Touchscreen

Energy Efficient

Electric insertion machines only consume electricity when they are working, unlike hydraulic ones that need to keep the oil pump running constantly. The average power consumption of an electric insertion machine is less than 0.4 KW, which is significantly lower than a hydraulic one that can consume up to 10 KW.

High Accuracy

These machines can adjust the force and stroke of the ram with high precision and repeatability, and the servo motor-driven ball screw can control the speed and position of the ram with minimal backlash or error. Electric machines allow you to control the ram by position or tonnage.  There is no “overtravel” or “undertravel” due to hydraulic viscosity fluctuations.

Faster Speed

Electric insertion machines can operate faster and more smoothly than hydraulic ones. They can also be integrated with a robot arm or a conveyor belt for automated loading and unloading of workpieces. Electric machines have “direct positioning” with immediate accelerations/decelerations, due to the ball screw/servo design.

Environmentally Friendly

Electric insertion machines do not use hydraulic oil, which can leak, spill, or contaminate the environment. Hydraulic oil also needs to be changed regularly, which adds to the cost and waste of the machine. Electric insertion machines eliminate these problems, delivering a clean and environmentally friendly solution.

Low Maintenance

Unlike hydraulic insertion machines, electric machines have fewer moving parts and do not require hydraulic fluid changes, spare parts, or valves. These components can wear out or break down over time, requiring frequent servicing and repairs – which drives up your maintenance expenses.

Hydraulic Insertion Machines

Hydraulic insertion machines use a hydraulic pump to generate pressure and move the ram that holds the fastener. The hydraulic pump is a device that uses oil to transmit power from a motor to a cylinder. Hydraulic insertion machines have several drawbacks compared to electric ones.

Energy Wasting

Hydraulic insertion machines consume more energy than electric ones because they need to keep the oil pump running even when they are not working. The oil pump also generates heat and noise that can affect the performance of the machine.

Lower Accuracy/Repeatability

Hydraulic machines have difficulty adjusting the force and stroke of the ram with high precision and repeatability. The hydraulic pump can cause variations in pressure from heat build-up or oil viscosity changes. Many Hydraulic insertion machines are programmed by tonnage and not position. Hydraulic viscosity fluctuations can occur, causing “overtravel” or “undertravel” of ram.

Slower Speed Changes

These machines operate slower and less smoothly than electric ones. Hydraulic insertion machines use fluids, valves, and the transfer of electrical signals, which create some lag in speed changes and accelerations.

Factory Floor

Environmentally Harmful

Hydraulic insertion machines use hydraulic oil, which can cause environmental problems if it leaks, spills, or contaminates the surroundings. Hydraulic oil also needs to be disposed of properly after it is used up, which adds to the cost and waste of the machine.

High Maintenance

Hydraulic insertion machines have more moving parts and require hydraulic fluid changes, spare parts, valves, and maintenance expenses. Hydraulic insertion machines have more components that can wear out or break down over time and need regular servicing and repairs.

PressOne Electric Insertion Machine

When it comes to accuracy, productivity, energy saving, environmental friendliness, and low maintenance, electric insertion machines are superior to hydraulic ones. Automec is proud to be the exclusive North American distributor of the PressOne Electric Insertion Machine, the first and only fully electric insertion machine in the industry.

If you are interested in learning more about the PressOne, please contact us today. We would be happy to answer your questions and provide you with a quote.

Insertion Machine Comparison: PressOne Electric vs. Traditional Hydraulic

PressOne Electric Insertion Machine Traditional Hydraulic Insertion Machine
Motor Servo motor-driven ball screw Hydraulic motor, pump, and fluids
Energy Usage Low. Average power consumption is less than 0.4 KW. It consumes less electricity, as it only uses energy when in motion. High. Average power consumption up to 10 KW. Hydraulic insertion machines consume more energy than electric ones because they need to keep the oil pump running even when they are not working. This makes them less efficient and expensive to run and maintain.
Accuracy High. Electric insertion machines can adjust the force and stroke of the ram with high precision and repeatability. The servo motor-driven ball screw can control the speed and position of the ram with minimal backlash or error. Electric machines allow you to control the ram by position or tonnage. There is no “overtravel” or “undertravel” due to hydraulic viscosity fluctuations. Low. Hydraulic insertion machines have difficulty adjusting the force and stroke of the ram with high precision and repeatability. The hydraulic pump can cause variations in pressure from heat build-up or oil viscosity changes. Many Hydraulic insertion machines are programmed by tonnage and not position. Hydraulic viscosity fluctuations occur allowing for the possibility of “overtravel” or “undertravel” of ram.
Speed Faster. Electric insertion machines can operate faster and more smoothly than hydraulic ones. Electric machines have “direct positioning” with immediate accelerations/decelerations, due to the ball screw/servo design. Electric insertion machines can also be integrated with a robot arm or a conveyor belt for automated loading and unloading of workpieces. Slower. Hydraulic insertion machines operate slower and less smoothly than electric ones. Hydraulic machines use fluids, valves, and the transfer of electrical signals, which create some lag in speed changes and accelerations.
Environmental Effects Positive. Electric insertion machines are more environmentally friendly because they consume less energy and do not use hydraulic oil, which can contaminate surrounding areas. Negative. Hydraulic oil can cause environmental problems if it leaks, spills, or contaminates the surroundings. Hydraulic oil also needs to be disposed of properly after it is used up, which adds to the cost and waste of the machine.
Maintenance Low. Electric insertion machines have fewer moving parts and do not require hydraulic fluid changes, spare parts, valves, or maintenance expenses. High. Hydraulic insertion machines have more moving parts and require hydraulic fluid changes, spare parts, valves, or maintenance expenses. Hydraulic insertion machines have more components that can wear out or break down over time and need constant servicing and repairs.
Cost Effectiveness High. Electric machines eliminate the need for hydraulic fluid changes, spare parts, valves, and maintenance expenses, saving time and money for the user. Low. The high maintenance cost and lower accuracy and productivity of hydraulic insertion machines make them less cost effective for the user.

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