DC servo-drive DST2

for drive systemsfor pressesregenerative

Overview
Baumüller supply complete drive and control systems for eccentric servo presses, delivering increased productivity, improved part quality and greater process flexibility compared with conventional hydraulic or mechanical presses. Solutions range from individual motors and converters to fully integrated drive packages including control platforms and software templates for fast commissioning.

Scope of the system solution

• Complete main drive system: high-torque DST2 motors, b maXX servo converters and modular power electronics
• Control cabinets: standard or fully wired special cabinets with water-cooling and EMC measures
• Control platform and software package: PLC templates, HMI visualizations and predefined interfaces
• Engineering services: dimensioning, ProSimulation digital twin, simulation and commissioning

Key components

• DST2 high-torque motors optimized for very high peak torque and low inertia
• b maXX servo drives and high-power modules (examples: b maXX 5100, b maXX 5500)
• Rectifier/regenerative feedback units and customer-matched energy stores (capacitors or custom units)
• Drive-integrated PLC / scalable Box-PC control platforms (e.g. b maXX PCC-04)

Typical functions & machine features

• Motion profile generation and execution for forming cycles
• Load distribution and synchronization across multiple motors (master–slave)
• Standardized control interfaces for integration with higher-level process control
• Setup, HMI and diagnostic functions with ready-made PLC templates
• Energy management and recovery with options for energy stores to reduce grid connection power

Benefits of servo presses

• Shorter cycle times and higher throughput
• Improved part quality and reduced tool wear thanks to precise motion control
• Lower energy consumption through regenerative feedback and intelligent energy storage
• Greater process flexibility via programmable motion profiles

Applications & scale
Applicable to eccentric press sizes from <100 t up to 3000 t. Typical uses include new machine builds and retrofit projects where modular drive systems enable multi-motor topologies and simplified spare parts management.

Engineering & simulation
ProSimulation (digital twin) models the full drive topology including nonlinear eccentric mechanics, gearing, motors, converters and energy stores to optimize drive sizing, minimize grid load and increase functional reliability before commissioning.

Control & software
The software package includes motion profiles, energy management, diagnostics and PLC/HMI templates for rapid commissioning. Control platforms are scalable and provide multiple interfaces for flexible machine architectures and web-based maintenance.

Control cabinet & hardware advantages

• Modular cabinet design and combinable modules
• Water-cooling connections and compact space-saving layouts
• Symmetrical load distribution and EMC mitigation options
• DC-link quick discharge and UPS options for drives and control units
• Completely wired special cabinets available (planning → production → assembly → installation)

Example system
Example: a complete drive system for a 3,000 t eccentric press using modular b maXX converter electronics with DST2 motors, rectifiers/regenerative units and a tailored energy store to enable multi-motor topologies and optimized energy usage.

Services & lifecycle
Baumüller provides global engineering, delivery and commissioning plus lifecycle services such as maintenance concepts and remote support. Offerings range from single components to complete drive systems adapted to customer requirements.

Technical specifications

• Press sizes: <100 t – 3000 t
• Motor family: DST2 high-torque motors (low inertia, high peak torque)
• Servo drives / converters: b maXX family (e.g. b maXX 5100, b maXX 5500)
• Energy: regenerative units, rectifiers, energy stores (capacitor-based buffering) and energy management
• Control platforms: scalable Box-PC solutions and drive-integrated PLC options
• Software: servo-press templates including motion profiles, energy management and diagnostics
• Control cabinets: modular, water-cooled options, DC-link discharge and UPS integration
• Engineering tools: ProSimulation (digital twin), sizemaXX, ProDrive