放電精密加工研究所 List of Products and Services

"ZENFormer plus" enables high-precision molding through a withdrawal method that simultaneously lowers the punch and die, reducing density differences in the axial direction, and achieves high-quality mass production through parallel control. By adopting an easily removable die set system, external setup is possible. This significantly reduces equipment downtime and simplifies cleaning. Additionally, during standby, power consumption is limited to only what is necessary for the control circuit. During production operation, the servo motor is utilized as a generator to regenerate deceleration energy, thereby reducing power consumption during continuous operation. 【Features of ZENFormer plus】 ■ Simultaneous lowering of punch and die ■ Achieves high-quality mass production through parallel control ■ Standby power consumption is limited to only what is necessary for the control circuit ■ Reduces power consumption during continuous operation by regenerating deceleration energy *For more details, please refer to the PDF document or feel free to contact us.

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We would like to introduce a molding case using the direct drive digital servo press "ZENFormer torque." It enables high-precision molding of carbon fiber resin across various fibers and forms, such as cross materials, UD materials, and non-woven fabrics. High-precision parallel pressing allows for bending, R-forming, deep drawing, and detailed molding. Additionally, in the flat plate molding of CFRTP, the high-precision parallel pressing of this product allows for molding characteristics equal to or better than those achieved with hydraulic presses at less than half the molding load. 【Features of ZENFormer torque】 ■ High-precision molding of carbon fiber resin is possible across various fibers and forms, such as cross materials, UD materials, and non-woven fabrics. ■ In flat plate molding of CFRTP, it achieves molding characteristics equal to or better than those of hydraulic presses at less than half the molding load. *For more details, please refer to the PDF document or feel free to contact us.

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When cutting film, traditionally, due to the variation in the bottom dead center of the press machine, thicker separators were used for backing, and the blade tip was inserted deeply for processing. With the 'ZENFormer nano', which has a bottom dead center repeat accuracy in the micron range, the variation in the bottom dead center can be reduced to a few micrometers, allowing for the use of ultra-thin separators. Additionally, by controlling the blade tip depth in microns and performing a just-cut on only the first layer to be cut, we eliminated the generation of substrate debris and the crushing and curling of cut edges caused by excessive blade pressure, achieving stability and improvement in product quality. 【Features of ZENFormer nano】 <Half-cutting of multilayer films> ■ Variation in the bottom dead center can be reduced to a few micrometers ■ Allows for the use of ultra-thin separators *For more details, please refer to the PDF document or feel free to contact us.

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We would like to introduce a molding case using the direct drive digital servo press "ZENFormer (Double Slide)." The high-precision protrusion molding of metal separators begins with the parallel control of the outer slide, uniformly constraining the large area of thin sheet across the entire surface. By applying concentrated pressure in the center of the inner slide, we achieve high precision in protruding the central flow path, resulting in high flatness across the entire flow path. Additionally, by performing shearing from both the upper and lower sides, we mold a good surface without burrs on the processed surface. 【Features of ZENFormer (Double Slide)】 <Metal Separator for Fuel Cells> ■ Uniformly constrains large areas of thin sheets through parallel control of the outer slide ■ Achieves high flatness across the entire flow path by precisely protruding the central flow path with concentrated pressure from the inner slide *For more details, please refer to the PDF materials or feel free to contact us.

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When forming parts that generate eccentric loads, such as automotive camshaft sprockets, "ZENFormer" enables step processing that disperses the pressing force by combining punches of different lengths. This reduces the forming load, allowing for cost reduction and space-saving in press and mold equipment, as well as extending the lifespan of molds. Additionally, with current detection sensors, we have established a new laminated technology that maintains magnetic characteristics similar to conventional products while using inexpensive directional electromagnetic steel sheets, achieving a significant cost reduction of materials to less than one-tenth. 【Case Overview】 <Automotive Camshaft Sprocket> ■ Step processing that disperses the pressing force by combining punches of different lengths is possible ■ Reduces forming load ■ Extends mold lifespan *For more details, please refer to the PDF materials or feel free to contact us.

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The "ZENFormer plus" is a direct-acting digital servo press machine for powder molding that operates two slides, upper and lower, in a compound manner. Since the motion of both the upper and lower can be freely set, it enables molding using the "withdrawal method," which achieves compression performance equivalent to the double-press method. By adopting a delta configuration that independently controls three axes and a nut drive structure, it has achieved compactness while maintaining parallel control. This parallel control allows for the molding of multiple pieces in ceramics and metal powder applications. Additionally, it generates electricity (regenerative) from the deceleration energy of the servo motor, keeping the power consumption low during continuous operation. 【Features】 ■ Environmentally friendly oil-free hydraulic and regenerative mechanism ■ Reduction in power consumption and operating oil volume ■ Reduced vibration and noise ■ Achieves parallel control with the "delta method," operating the upper and lower using three servo motors and ball screws *For more details, please refer to the PDF document or feel free to contact us.

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The "ZENFormer torque" is a linear digital servo press machine suitable for molding composite materials. It allows for molding that combines load control and position control, maintaining parallelism of the slide during both position control, where micron-level bottom dead center settings can be made, and load control. With a nut drive structure, it ensures a long stroke of approximately 1 meter, accommodating large and deep drawing molds. In pressure holding mode, it can maintain pressure for up to 180 minutes in one-minute increments, while in high cycle mode, it can set pressure holding for up to 320 seconds in 0.01-second increments. 【Features】 ■ High-precision processing combining load control and position control ■ Approximately 1 meter of ultra-long stroke ■ Long pressure holding time of up to 180 minutes ■ ZENFormer’s unique parallel pressure, high precision, and visualization/numerical representation *For more details, please refer to the PDF document or feel free to contact us.

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The "ZENFormer nano" is a compact direct-drive digital servo press machine achieved through a structure that places the motor at the bottom. With ZENFormer’s unique mechanism of "4-axis independent control," it realizes complete parallel control. The repeat accuracy at the bottom dead center is also in the micron range, allowing for molding compatible with multi-materials such as metal foils, functional films, and resins. With a rich series lineup in low load ranges of 5t, 10t, 20t, and 30t, we propose minimal equipment specifications for molding that does not require large loads. As a mechanical press with low environmental impact, it is also ideal for replacing hydraulic presses. 【Features】 - Achieves compactness with an "under-drive structure" that places the servo motor at the bottom - Improved stability due to a lower center of gravity - A rich series lineup in low load ranges of 5t, 10t, 20t, and 30t - High applicability to accommodate multi-materials - ZENFormer’s unique parallel pressure application, high precision, and visualization/numerical representation *For more details, please refer to the PDF document or feel free to contact us.

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The "ZENFormer Double Slide" is a linear digital servo press machine with two slides that move independently. Its double-action mechanism allows for process shortening and the development of innovative construction methods. Since each slide, inner and outer, is controlled independently with a 4-axis system, it enables high-precision molding at the micron level, just like conventional models, while maintaining constant parallelism. As a mechanical press with low environmental impact, it is also ideal for replacing hydraulic presses. 【Features】 ■ Enables process shortening and the development of innovative construction methods ■ Two slides moving with unique 4-axis independent control for complete parallel control of inner and outer slides ■ ZENFormer’s unique parallel pressure application, high precision, and visualization/numerical representation *For more details, please refer to the PDF materials or feel free to contact us.

• Processing Technology

"ZENFormer" is a digital servo press machine that achieves complete parallel control through its unique mechanism of "four-axis independent control," which operates a single slide using four ball screws. By employing linear scales installed at the four corners of the slide, it performs full closed-loop feedback control, ensuring that the slide remains parallel at all times. It also continuously corrects variations in the bottom dead center position, minimizing them to achieve high-precision molding. Additionally, it is capable of generating full power throughout the entire stroke, something that conventional mechanical presses cannot achieve. As a mechanical press with low environmental impact, it is also ideal for replacing hydraulic presses. 【Features】 ■ Strong parallel control against eccentric loads ■ Full power generation possible at any position during the stroke ■ Micron-level repeat accuracy at the bottom dead center ■ Numerical and visual representation of press processing *For more details, please refer to the PDF document or feel free to contact us.

• Processing Technology