Smart sheet metal processing: DELTA-TECH relies on CytroForce

The DELTA–TECH Group is expanding its sheet metal forming capacity with a groundbreaking edge bending machine. At its heart: the self-contained servo-hydraulic actuator CytroForce from Bosch Rexroth. The result: maximum process quality and energy efficiency in a minimal footprint.

Summary:
The DELTA–TECH Group has equipped its new DLB 1500 BRDM edge bending machine with the self-contained servo-hydraulic actuator CytroForce from Bosch Rexroth. The CytroForce's high power density and accuracy enable high-precision sheet metal forming with a positioning accuracy of 10 µm and a repeatability of 5 µm. Thanks to its energy-on-demand drive based on Sytronix technology, the CytroForce operates energy efficient. According to customer data, the integrated design reduces energy consumption up to 80% and the oil volume is cut by 90%. With CytroForce, DELTA–TECH benefits from a more compact machine design, simplified integration, and lower overall costs from engineering to operation and maintenance. This translates into significant competitive advantages for DELTA-TECH as a machine manufacturer.

New edge bending machine with CytroForce

Hungarian mechanical engineering is known for its pragmatic and efficient solutions to technical challenges. The DELTA–TECH Group follows this tradition in its customer machines as well as in its own production. A prime example of this typical combination of high performance and efficiency is the innovative DLB 1500 BRDM edge bending machine with a self-contained servo-hydraulic CytroForce actuator from Bosch Rexroth, used to expand sheet metal processing capacity at the Győr site.

Processing sheet metal precisely and efficiently

The DELTA-TECH Group employs more than 100 specialists at three locations in Hungary. With design and engineering teams, most of whom have 30 or more years of experience, DELTA-TECH develops sophisticated solutions for industries such as automotive and energy, focusing on the following areas:

• Special machines
• complete production lines
• Machine tools and assembly systems
• Testing and quality assurance systems

DELTA-TECH relies on state-of-the-art technologies and production machinery for its machines and systems. Sheet metal processing takes place at the two locations in Bátonyterenye and Győr. To complement the production of large formats and series in Bátonyterenye, sheet metal production in Győr was recently expanded with a self-developed laser cutting robot and the innovative DLB 1500 BRDM edge bending machine with CytroForce.

High-precision hydraulic drive

The edge bending machine with CytroForce utilizes DELTA-TECH for more demanding bending operations. A key reason for choosing the self-contained CytroForce servo-hydraulic actuator lies in its high repeatability. In sheet metal bending machines, the accuracy of the upper tool's movement is a critical factor. Even a slight stroke deviation of 0.07 mm at the bending tool can significantly affect the process and, for example, alter the bending angle by as much as 1°. The CytroForce hydraulic units used by DELTA-TECH support the high precision requirements in sheet metal bending with a positioning accuracy of 10 µm and a repeatability of 5 µm. With the new machine, DELTA-TECH can bend sheets up to 1500 mm wide, with a 4-actuator servo system from Bosch Rexroth precisely controlling the inner sheet metal stop.

Stress-free machine frame

As the second most critical component for the precision of sheet metal bending machines, DELTA-TECH has developed a stress-free machine frame whose optimal dimensions were determined using finite element analysis (FEA). This minimizes tool displacement under maximum load but does not eliminate it completely. Therefore, the frame's deformation is additionally measured with an analog caliper and transmitted to the Cybelec software, which controls the bending machine, for compensation.

More benefits without a hydraulic power unit

The modular CytroForce servo-hydraulic actuator from Bosch Rexroth is based on the Sytronix variable-speed, energy-on-demand drive. Directly attached to this energy-efficient unit, consisting of a servo motor and a hydraulic constant or variable displacement pump, are a control block and a differential or tandem cylinder. All hydraulic components and interfaces have been optimized for fluid flow using state-of-the-art methods.
The result: reduced noise emissions and high performance in a minimal footprint.

Together with the tank, safety valves and sensors, the CytroForce modules form a highly compact and efficient servo-hydraulic actuator with a closed fluid circuit. As a result, the edge bending machine with CytroForce requires only 13 liters of oil – that's 90% less oil volume than a conventional hydraulic drive with a power unit and throttle control.

Power on demand saves up to 80% energy

The self-contained CytroForce hydraulic actuator is delivered pre-configured as an out-of-the-box solution made up of flow-optimized standard modules. Thanks to the Sytronix variable-speed drive, CytroForce only consumes as much power as is required at each stage of the bending cycle. This power-on-demand approach means the edge bending machine with CytroForce consumes only 16 kWh of power, resulting in up to 80 percent energy saving for DELTA–TECH.

Plug & Produce with Standards

Another advantage of Bosch Rexroth's CytroForce solution is its unified drive and control concept, which follows a plug-and-produce approach. This includes an intelligent control unit with integrated hydraulic functions and standardized interfaces. Thanks to its purely electrical connection, the pre-configured servo-hydraulic CytroForce actuator can be treated like an electric drive at the control level; only the electrical components and the higher-level control system need to be connected.

With the self-contained servo-hydraulic actuator CytroForce as a hydraulic direct drive, the DELTA-TECH Group sets technological and economic standards in sheet metal processing – in terms of repeatability, space requirements and energy efficiency.

Furthermore, the integrated servo-hydraulic CytroForce approach with electric drive and encapsulated fluid circuit minimizes the total cost of the machine over its lifetime – from simpler engineering and integration to cost-efficient operation with low maintenance requirements.

“The collaboration between DELTA-TECH and Bosch Rexroth demonstrates how bending processes can be optimized through modern servo-hydraulic drive technology,” concluded Herman Lajos. “CytroForce combines power, micrometer-level precision, energy efficiency, and compact integration into a technically compelling solution that creates long-term economic added value for us as machine manufacturers and operators.”