Baumüller presents smart drive solutions for presses

The Baumüller servo-press system solution combines the DST2 high-torque motor, the b maXX servo drive, the b maXX mains inverter, control technology, and software in a complete package.

Baumüller will exhibit drive and automation systems for metal-forming machinery at Euroblech in Hanover, Germany, taking place from October 20 to 23, 2026, in Hall 27 at Stand C155. The company will showcase an operational mini servo press alongside a live demonstration of a drive combination featuring a Baumüller DST2 high-torque motor paired with a Nidec Desch Servox gearbox.

Direct Drive Configurations and Process Optimization
Servo eccentric presses provide operational adjustments over conventional mechanical systems by enabling programmable motion profiles during forming cycles. This allows adjustments in cycle time, tool wear reduction, and energy usage while minimizing mechanical wear components. Baumüller’s servo press system package includes DST2 high-torque motors, b maXX mains inverters, b maXX servo drives, control technology, and application software.

Flywheel Press Modernization and Retrofit Architecture
Mechanical flywheel presses can be converted into servo eccentric presses with targeted design modifications. Following the removal of legacy drive systems and mechanical inspection, DST2 high-torque motors integrate directly into existing gearbox configurations alongside b maXX servo drives and control units. This conversion eliminates mechanical wear parts, including friction clutches, mechanical brakes, and V-belts, lowering ongoing maintenance requirements.




Common DC-Link and Regenerative Energy Management
Baumüller’s drive structure utilizes a common Direct Current (DC) link connecting the b maXX grid-connected regenerative inverter with b maXX servo inverters:

• Peak Load Shaving: Capacitors connected to the shared DC link store electrical energy to buffer process-induced load peaks, lowering the required utility connection capacity and associated infrastructure costs.
• Energy Recuperation: Braking energy generated during deceleration phases following a forming stroke is captured in the DC link and redirected to subsequent machine movements.
• Voltage Boost: The system increases intermediate DC link voltage from 400 volts to 760 volts, shifting the motor characteristic curve upward to expand the operational speed range and permit smaller motor dimensions.
• Mains Regeneration: The b maXX active mains inverter feeds surplus kinetic and electrical energy back into the supply grid, reducing the size of or eliminating auxiliary braking resistors and decreasing control cabinet dimensions.

The b maXX grid-connected inverter increases the DC link voltage (1), thereby extending the motor’s speed range (2) and feeding surplus energy back into the grid (3). This requires a common DC link.

Additional Context
This section details technical specifications not included in the original news release.

Baumüller DST2 series direct-drive units are water-cooled, permanent-magnet synchronous torque motors engineered with high pole counts to deliver maximum torque density at low rotational speeds, eliminating the need for intermediate reduction gear stages. These motors utilize integrated liquid cooling jackets, high-resolution absolute optical or magnetic encoders, and permanent magnets on the rotor to maintain high overload capability and precise angular positioning during rapid acceleration and reversal phases.

The b maXX series modular servo drives interface over high-speed industrial Ethernet communication fieldbuses, including EtherCAT, PROFINET, and Ethernet POWERLINK, supporting synchronized multi-axis motion control with microsecond-level cycle times. The active front-end inverter employs active power factor correction and bidirectional insulated-gate bipolar transistor switching stages, allowing dynamic four-quadrant operation with minimal harmonic distortion on the AC power grid.

Edited by Romila DSilva, Induportals Editor, with AI assistance.