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 for Electrical Connector Terminal Stamping: Setup Guide

admin

Electrical connector terminal stamping is one of the most demanding servo press applications —high SPM, tight tolerances, and complex progressive dies.

## Typical Requirements

- Part: connector terminals, 0.2-0.6mm phosphor bronze or copper alloy
- Tolerance: ?0.02mm on critical dimensions
- SPM: 200-800 SPM (high-speed applications)
- Die: progressive die, 8-24 stations

## Press Selection Criteria

For terminal stamping, direct-drive servo presses are preferred over gear-reducer types:
- No backlash in drive train
- Faster response to motion profile changes
- Better repeatability at high SPM

Recommended: Aida NS series, Komatsu H1F series, or equivalent direct-drive presses.

## Motion Profile Optimization

At 400 SPM, each stroke takes 150ms. Typical profile breakdown:
- Approach (TDC to 5mm above material): 60ms at maximum speed
- Forming zone (5mm above to BDC): 30ms at controlled speed
- Dwell at BDC: 5ms (for spring-back control)
- Return (BDC to TDC): 55ms

**Key parameter:** Forming speed in the last 5mm before BDC. For phosphor bronze:
- Too fast (>200mm/s): burr formation, die wear
- Optimal: 80-150mm/s
- Too slow: cycle time penalty

## Feed System Synchronization

Progressive die stamping requires precise synchronization between press and material feed:
- Feed timing: typically 270-330? of press cycle (feed during upstroke)
- Feed length tolerance: ?0.05mm for 8mm pitch
- Use press encoder output to trigger feed servo

## Quality Control Points

- Check first article after every die change: measure 5 critical dimensions
- Monitor tonnage signature —deviation >5% from baseline indicates die wear or material variation
- Burr height: measure every 2 hours, replace punch when burr >0.02mm

lisa_quality

Connector terminal inspection at 400+ SPM requires automated vision. We use a line-scan camera synced to the press stroke counter. Every terminal gets inspected for width, bend angle, and surface defects. Reject rate on the servo press is 0.02% vs 0.3% on our old mechanical. The servo's consistency makes the vision system's job much easier.

dave_toolmaker

Progressive dies for connector terminals are the most precise dies I build. Pilot pin clearance is 0.005mm, punch-to-die clearance is 0.003-0.005mm on the critical features. The servo press's low-vibration operation is essential —on a mechanical press, the impact shock causes pilot pin wear 3x faster.