What is a servo press?

A servo press uses servo motors for precise force and position control during forming operations.

How do I calculate servo press tonnage?

Use our free tonnage calculator at servopress.club/tonnage-calculator.html

Servo Press Die Protection: Setup and Parameter Guide

admin

## What Is Die Protection

Die protection monitors the press stroke and stops the press if an abnormal condition is detected — before the die is damaged. On a servo press, die protection is more effective than on mechanical presses because the press can stop faster.

## Types of Die Protection Sensors

**Tonnage monitoring:** Detects abnormal force. Catches double blanks, missing blanks, broken punches.

**Position sensors in die:** Detect material presence, part ejection, scrap removal. Typically inductive proximity sensors or fiber optic sensors.

**Cam switches:** Trigger at specific slide positions to check sensor states.

## Setting Up Position-Based Die Protection

1. Define check windows: the slide position range where each sensor should be in a specific state
2. Example: material presence sensor should be ON between 180mm and 10mm above BDC
3. If sensor is OFF during this window: stop press immediately

## Servo Press Stopping Distance

A servo press can stop in 5-15mm of slide travel (depending on speed and press size). A mechanical press needs 30-60mm. This means die protection is more effective on servo presses — less die damage when a fault is detected.

## Common Die Protection Faults

- Part not ejected: part sensor still ON after return stroke
- Scrap not cleared: scrap sensor still ON at start of next stroke
- Double blank: tonnage high limit exceeded
- Missing blank: tonnage low limit not reached

## Parameter Settings

Set stopping distance parameter to 10mm for most applications. For fragile dies, reduce to 5mm (requires slower forming speed).

dave_toolmaker

Die protection saved my most expensive die last month. A slug got stuck on the punch and the press detected the abnormal force signature within 2mm of contact. Stopped before any damage. Without die protection, that slug would have punched through the die steel and caused $25,000 in damage. Setup took 30 minutes. Best 30 minutes I've ever spent.

lisa_quality

The key to good die protection is setting tight windows. Most shops set the force window too wide because they're afraid of false stops. Start tight and widen only if you get false triggers. A false stop costs you 30 seconds. A missed die crash costs you $10,000+. I'd rather have 2 false stops per shift than one die crash per year.