INOMAX ACS580 & ACS880 – Forging Machine Solutions

High-Performance Variable Frequency Drives for Hydraulic Forging Presses, Hammers & Ring Rolling Mills

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Overview

Forging is one of the most demanding metal forming processes. Hydraulic forging presses, counterblow hammers, and ring rolling mills operate under extreme conditions: high shock loads, continuous heavy-duty cycles, intense vibration, and harsh environments with scale, dust, and heat. The electric motors driving hydraulic pumps, screw mechanisms, and manipulation equipment must deliver reliable performance day after day, year after year.

At Inomax Technology, we supply ACS580 (general purpose) and ACS880 (high-performance) variable frequency drives to forging equipment manufacturers, retrofitters, and forges worldwide. Our drives are engineered for demanding forging applications: high overload capacity (200% for 60s) for peak pressure demands, Direct Torque Control (DTC) with <5 ms torque response for instantaneous pressure buildup, master‑slave torque control for multi-pump systems, regenerative AFE options for energy recovery on downhill conveyors and counterbalance systems, and harsh environment protection with conformal coating as standard.

We are also actively expanding our global partner network. If you are a distributor, system integrator, forging equipment OEM, or retrofit specialist, we invite you to explore a partnership with INOMAX – factory‑direct pricing, technical support, market protection, and proven technology trusted by forging facilities worldwide.

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Why Forging Machines Need High-Performance VFDs

The Challenge – High Shock Loads & Peak Pressure Demands

Forging is characterized by extreme peak power demands. When a hydraulic press delivers the final blow on a large ingot, the pump motor must deliver maximum torque for a short duration. Traditional fixed-speed pump systems are grossly oversized for the continuous load to handle the peak – wasting energy during idle and light-load periods. VFD-controlled variable-speed pumps match motor speed to real-time demand, dramatically reducing energy consumption while delivering the required peak torque.

Energy savings of 30-60% are typical when retrofitting fixed-volume pump systems with variable-speed VFD control.

Precision Control for Consistent Forgings

Consistent forging dimensions require precise control of ram position and speed. Traditional systems use proportional valves to meter flow – wasteful and imprecise. VFDs with closed-loop control offer:

• Speed accuracy ±0.5% (ACS580) to ±0.01% (ACS880 with encoder) – Consistent ram speed for repeatable forgings

• Built‑in PID control – Maintains precise hydraulic pressure regardless of load variations

• Fast torque response (<5 ms on ACS880) – Instantaneous pressure buildup at the start of the forging stroke

Multi-Pump Systems – Load Sharing & Sequencing

Large forging presses (5,000-50,000 tons) often use multiple pumps in parallel – high-flow pumps for fast approach, high-pressure pumps for forging. Our drives support:

• Master‑slave torque control – Perfect load sharing when multiple pumps operate simultaneously

• Sequential pump control – Start/stop pumps based on demand, saving energy during light loads

• Common DC bus – Energy sharing between pumps; reduced input power

Energy Recovery – Downhill Conveyors & Counterbalance Systems

Forging facilities often have downhill conveyors (scale removal, part handling) and counterbalance systems that regenerate energy. Traditional systems waste this energy as heat. Our ACS880 AFE drives return >95% of braking energy to the grid, reducing electrical costs by 15-25% in regenerative applications.

Harsh Environment Protection

Forging plants are among the harshest environments for electrical equipment: extreme heat (radiant heat from furnaces), conductive dust (scale, graphite), vibration, and humidity. Our drives feature:

• Conformal-coated circuit boards as standard – Protects against conductive dust and moisture

• IP54/IP66 enclosure options – For installation near the press

• Wide operating temperature range – -15°C to +50°C without derating

• Stainless steel hardware options for critical components

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Key Technologies – Professional Solutions for Forging Equipment

1. High Overload Capacity – Handling Peak Forging Demands

Forging presses require short-duration peak torque – often 150-200% of rated motor torque for 10-60 seconds during the final blow. Our drives deliver:

• ACS880 – 200% torque for 60 seconds, 250% for 30 seconds (ACS890 multi-module)

• ACS580 – 150% for 60s (constant torque rating)

This means you can size the drive for the continuous load, not the peak – saving capital cost.

2. Direct Torque Control (DTC) – Instantaneous Pressure Buildup

ACS880 DTC technology updates the motor model 40,000 times per second, delivering instantaneous torque response without an encoder for most applications.

Why DTC matters for forging:

• Full torque at zero speed – Pressure builds instantly when the forging cycle starts; no waiting for pump spin-up

• Torque response <5 ms – Critical for synchronized multi-pump systems and precise ram control

• Speed accuracy ±0.01% with encoder – Precise ram positioning for closed-die forging

• No encoder needed for most applications – Higher reliability in vibrating, dusty environments

3. Master‑Slave Torque Control for Multi-Pump Presses

Large forging presses often have multiple pumps (e.g., 3 × 250 kW) feeding a common manifold. Without proper load sharing, one pump can carry most of the load, leading to overheating and premature failure.

How our master‑slave torque control works:

• Master drive operates in speed control

• Slave drives operate in torque control, receiving torque reference from master via internal drive-to-drive communication (XD2D) or fieldbus

• Result – All pumps produce identical torque; perfect load balance; eliminates uneven wear

• Redundant master capability – If master fails, any slave can automatically assume master role

4. Variable-Speed Pump Control – The Core Energy Saver

The primary function of a VFD in a hydraulic forging press is to control the speed of the pump motor. Instead of the pump running at full speed continuously, the drive ramps motor speed up and down based on real-time demand.

How it works:

• Pressure feedback – A pressure transducer in the hydraulic manifold provides real-time feedback (4-20mA or 0-10V)

• PID control – The drive compares actual pressure to setpoint and adjusts motor speed to maintain target pressure

• Demand-based speed – During low-demand phases (idle, approach, return), motor speed drops significantly – often to 20-40% of rated speed

• Energy savings – Power follows the affinity law: reducing speed by 50% reduces power consumption by approximately 87.5%

5. Regenerative AFE – Energy Recovery for Downhill Conveyors & Counterbalance

Forging facilities often have:

• Downhill conveyors – Scale conveyors, part handling conveyors that regenerate energy

• Counterbalance systems – Hydraulic or pneumatic systems that regenerate during the return stroke

Our ACS880 AFE drives return >95% of this regenerated energy to the grid, reducing electrical costs by 15-25% in applications with significant regenerative duty.

Key AFE benefits:

• THDi <5% at 80-100% load – Eliminates harmonic interference; meets IEEE 519 without external filters

• Unity power factor (>0.99) – Reduces utility penalties; maximizes transformer utilization

• Regenerative energy recovery – Returns >95% of braking energy to the grid

• Constant DC bus voltage – Immune to grid fluctuations common in industrial environments

6. Fieldbus Integration for Press Controllers

Forging presses use dedicated controllers from brands like SMS Group, Siempelkamp, Schuler, Fagor Arrasate, and others. Our drives support all major protocols:

• Profinet IO / Profinet IRT – For Siemens-based controllers (common in European presses)

• EtherNet/IP – For Rockwell-based controllers (common in North American presses)

• EtherCAT – For Beckhoff-based controllers (high‑performance synchronization)

• Profibus DP – For legacy controllers

• CANopen – For many European press controllers

• Modbus RTU/TCP – For universal compatibility

We provide complete GSDML, ESI, and EDS files, plus sample code for common forging press controllers.

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Forging Equipment Covered

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Technical Specifications – Professional Grade

ACS580 Series (Cost‑Effective for Auxiliary Drives & Smaller Presses)

ACS880 Series (High‑Performance for Main Press Drives)

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Real Projects – Proof of Performance

Our drives are used by forging equipment manufacturers, retrofitters, and forges worldwide.

Measured results from these installations:

• Energy savings on hydraulic pump retrofits: 35-55% (validated by power meters)

• Pump motor current balance (multi-pump master‑slave): within ±3%

• Regenerative conveyor energy recovery: 85-95% of braking energy returned to grid

• Press cycle time reduction: 5-10% (faster pressure buildup with DTC)

• Hydraulic oil temperature reduction: 10-15°C (reduced cooling requirement)

• Payback period: 8-18 months depending on duty cycle

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For Distributors, System Integrators & Forging Equipment Specialists

Why Partner with INOMAX?

Partnership Models

Distributor Support Program

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Frequently Asked Questions

Q1: How much energy can I save by adding VFDs to my hydraulic forging press?

Based on our case studies, typical energy savings range from 30% to 60% depending on your cycle:

• Long idle times between forgings – 50-60% savings (pump runs at low speed during idle)

• Multi-pressure cycles – 40-50% savings (pump speed matches each pressure level)

• High-duty cycles with minimal idle – 30-40% savings (still saves on approach and return strokes)

• Multi-pump systems with sequencing – 40-55% savings (pumps start/stop based on demand)

A typical 1,000-ton press operating 5,000 hours/year with $0.12/kWh electricity can save $30,000-$60,000 annually.

Q2: Can I retrofit my existing fixed-speed hydraulic forging press with a VFD?

Yes – and this is one of the most cost-effective energy efficiency upgrades available for forges. The retrofit typically includes:

• Installing the VFD between the main disconnect and the pump motor(s)

• Adding pressure transducers to the hydraulic manifold

• Configuring the drive(s) for pressure PID control

• Tuning the PID parameters for your specific press cycle

• For multi-pump systems, configuring master‑slave torque control

Most retrofits can be completed in 2-5 days. Payback is typically 8-18 months.

Q3: How does master‑slave torque control work for multi-pump forging presses?

In a multi-pump press (e.g., 3 pumps feeding a common manifold), the master drive operates in speed control. The slave drives operate in torque control, receiving torque reference from the master via internal drive-to-drive communication. This ensures all pumps produce identical torque regardless of individual pump characteristics – perfect load sharing, no fighting, reduced wear. If one pump fails, the others continue operating at reduced capacity.

Q4: What is the advantage of regenerative AFE for forging facilities?

Forging facilities often have downhill conveyors (scale removal, part handling) and counterbalance systems that regenerate energy. Without AFE, this energy is wasted as heat in braking resistors. With ACS880 AFE, >95% of this energy is returned to the grid – reducing electrical costs by 15-25% in applications with significant regenerative duty. AFE also provides ultra-low harmonics (THDi <5%) and unity power factor.

Q5: Can ACS880 handle the high starting torque required for large hydraulic pumps?

Yes. ACS880 DTC delivers 200% starting torque at 0 Hz without an encoder – more than enough for the largest hydraulic pumps. The drive also provides programmable S-curve acceleration to prevent hydraulic shock and mechanical stress on pumps and piping.

Q6: What is the expected service life of INOMAX drives in forging environments?

With proper maintenance, 20+ years. Forging plants are harsh – we recommend IP54/IP66 enclosures for drives installed near the press. Conformal coating (standard on all our drives) protects against conductive dust (scale, graphite). We also recommend regular cleaning of air filters and annual fan replacement.

Q7: What is the minimum order quantity (MOQ) for distributors?

No strict MOQ for initial orders. Volume discounts apply from 10 units per order. For OEM/private label, MOQ is negotiated.

Q8: What is the standard warranty period?

2 years from date of manufacture or 12 months from commissioning, whichever comes first. Extended warranty up to 5 years available.

Q9: What is your typical lead time?

Popular models (≤250 kW) – 3-5 working days from our China factory + shipping. Larger units (250-6,000 kW) – 2-4 weeks.

Q10: Do you offer market protection?

Yes. Exclusive territory agreements (subject to minimum commitment) and project registration. Registered projects are protected – we will not quote directly or work with other distributors on that project.

Q11: Can you customize drives for my OEM requirements?

Yes: private labeling, custom parameter presets for specific forging press models, special enclosures, modified firmware, custom voltage/frequency ranges.

Q12: What technical support can I expect for my customers?

Free pre-sales support: drive sizing, harmonic analysis, configuration recommendations, master‑slave setup. Post-sales: remote diagnostics (free), on-site commissioning (fee-based). Product training for your technical staff.

Q13: How does INOMAX compare to ABB, Siemens or Danfoss for forging applications?

We are legitimate competitors. Our ACS880 uses the same Direct Torque Control (DTC) technology as ABB ACS880. Performance specifications match or exceed competition. Price is 20-30% lower. Lead times are shorter. Customization is more flexible. Our master‑slave torque control and high overload capacity are specifically designed for multi-pump forging presses.

Q14: Do you offer retrofit kits for converting existing forging presses to variable speed?

Yes. We offer pre‑engineered retrofit packages including:

• Drive(s) sized for your pump motor(s)

• Pressure transducers (if needed)

• Pre‑configured parameters for your press type (master‑slave, PID pressure control)

• Wiring diagram and installation guide

• Commissioning checklist

Contact us with your press specifications for a quote.

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Ready to Partner with INOMAX?

Join a growing network of distributors, retrofit specialists, and forging equipment OEMs who have discovered that INOMAX delivers premium performance at a competitive price – with real factory support.

Apply for distributorship today:

• Fill out the form below with your company information and market focus

• We will contact you within 24 hours to discuss partnership terms

• Receive distributor pricing, marketing materials, and technical documentation