- Industry
- Automotive Manufacturing
- Solution
- Hydraulic bench press
- Project duration
- August 2016 – March 2017
- Engineering focus
- Mechanical design, hydraulic systems, CAD, FEA, prototyping
- Capacity
- Up to 100 tons of pressing force
The customer needed up to 100 tons of pressing force for automotive component forming, but the machine had to fit an existing cell rather than dictate a new one. Structural deflection, hydraulic efficiency, heat build-up and operator safety all had to be solved inside that envelope.
Long-term durability and ease of maintenance mattered as much as peak force. A press that holds tonnage but takes a day to service is not a production machine.
We developed a hydraulic press architecture around a double-acting cylinder, a high-strength structural frame, a closed-loop hydraulic circuit and a variable-displacement pump, with cooling, overload protection, interlocks and guarding designed in rather than bolted on.
FEA was run on the critical structural members to find high-stress regions, evaluate deformation and remove material that was not carrying load, while holding the required safety margins.
The prototype was put through high-load testing, thermal cycling, structural evaluation, hydraulic performance testing and repeatability testing before release.
Project overview
Redyna Technologies designed a high-capacity hydraulic bench press for automotive component manufacturing.
The system was designed to deliver up to 100 tons of pressing force while maintaining structural stability, precision, operator safety, reliability and compact installation requirements.
Key challenges
The project required solutions for:
- High pressing force
- Structural deflection
- Hydraulic efficiency
- Operator safety
- Overload protection
- Compact footprint
- Heat management
- Long-term durability
- Ease of maintenance
- Cost-effective construction
Redyna's engineering solution
A robust hydraulic press architecture was developed using:
- Double-acting hydraulic cylinder
- High-strength structural frame
- Closed-loop hydraulic circuit
- Variable-displacement pump
- Hydraulic cooling system
- Overload protection
- Safety interlocks
- Protective guarding
Mechanical and structural engineering
The press frame was designed using high-strength structural steel.
FEA was performed on critical components to:
- Identify high-stress regions
- Evaluate deformation
- Optimize structural geometry
- Reduce unnecessary material
- Maintain required safety margins
Hydraulic system
The hydraulic system incorporated a closed-loop architecture and variable-displacement pump to improve energy efficiency and provide controlled hydraulic flow.
Cooling provisions were incorporated to control hydraulic fluid temperature during extended operation.
Safety engineering
Safety features included:
- Hydraulic overload protection
- Pressure-release mechanisms
- Protective enclosures
- Safety interlocks
- Controlled operating conditions
Maintenance and serviceability
The design incorporated:
- Self-lubricating bearings
- Accessible hydraulic components
- Quick-release fluid connections
- Replaceable hydraulic seals
- Modular hydraulic power unit
Testing and results
The prototype was subjected to:
- High-load testing
- Thermal cycling
- Structural evaluation
- Hydraulic performance testing
- Repeatability testing
Business value
The press successfully delivered the required pressing force and demonstrated stable hydraulic pressure with minimal fluctuation.
The resulting machine provided a compact, robust and maintainable manufacturing solution capable of supporting high-force automotive component forming operations.
Redyna's value — one engineering and implementation pathway
- Requirements
- Concept
- Detailed design
- FEA
- Prototype
- Testing
- Production integration
100 tons
Pressing force
Stable, minimal fluctuation
Hydraulic pressure
Aug 2016 – Mar 2017
Programme