200 Ton Eccentric Press Manufacturing: Automotive and Heavy Industry Power

In the industrial manufacturing sector, some machines not only facilitate the work of workshops but also completely rewrite the production identity of that factory. Where we have now reached the absolute peak of mechanical limits in metal forming and power needs to be controlled with massive engineering, the reign belongs to 200-ton eccentric press machines. These giant power units are at the heart of the most demanding projects; from tractor parts to construction machinery bodies, from railway sub-industry to massive automotive fasteners.

As Karmaksan Machine, carrying the heaviest burdens of the industry since 1988, we take these 200-ton industry giants from being an ordinary pile of iron and transform them into smart production stations purely with the "Industry 4.0" vision. Especially for our industrialists in search of multi-station heavy casting mold presses, we realize brand new generation productions with "Double Gear" and "Overload Protection" that go beyond the standards at this tonnage.

Zero Flex Strategy: Heat-Treated Steel Body

When talking about a 200-ton machine, our biggest enemy is "flexing", that is, metal fatigue. In one second, a shockwave of 200,000 kilograms lands on your mold and lifts. This terrifying seismic effect shatters standard cast iron bodies. Therefore, every 200-ton machine coming off the Karmaksan production line has a fully heat-treated steel body (with H-Frame or C-Frame options) architecture.

Heavy ST-52 and ST-44 steel plates cut on giant laser machines are woven with special alloy robotic welds. But the work doesn't end there. This massive welded structure is kept in special stress-relieving furnaces for days. This process zeros all the stress in the molecular structure of the steel. In this way, especially in our machines used as automotive chassis presses, there is not even a deviation of a thousandth of a millimeter between the giant table where the mold is attached and the ram. The life of your molds doubles, and the parts you produce provide a perfect fit on the assembly line.

The Peak of Torque: Double Gear Reducer Transmission

Trying to transfer a force of 200 tons directly from a flywheel to the crankshaft causes the machine's motor to burn out or the system to stall. We manage this massive power with the double gear reducer press mechanism, which transforms motor RPM into torque (crushing power) rather than speed. Specially ground and case-hardened helical gear groups amplify the power step by step and transmit it to the crankshaft.

In addition, since very wide working tables (e.g., 1200x2000 mm) are generally used in 200-ton presses, it is impossible to apply power to the ram from a single point. To apply simultaneous and parallel pressure to this wide table, we use the "Double Pitman" system. Thanks to this, in your heavy tonnage sheet metal forming operations, there is absolutely no axial sliding (offset) in the mold areas corresponding to the right or left corners of the part.

Critical Safety Network: Overload Protection Valve

A minor operator error on a 200-ton machine (feeding double sheets into the mold or a setting error) results in the body cracking or the massive crankshaft splitting in two in traditional machines. Karmaksan engineering prevents this disaster with a "Hydraulic Fuse". The overload protection valve placed inside the machine's ram violently discharges the oil inside in the very first millisecond the pressure exceeds 200 tons.

The mechanical connection of the machine is instantly released, the strike does not occur, and both your multi-million press and your priceless molds are saved. By simply pressing a button on the panel, oil is pumped back into the system, and production safely resumes from where it left off within 2 minutes.

Industry 4.0 Features of Our 200-Ton Giants

• Advanced Pneumatic (Air) Clutch: A massive air pressure clutch/brake system that stops the 200-ton giant mass in a millisecond, fully complies with CE norms, and does not overheat.
• Central PLC Brain: A smart touch HMI panel that allows you to perform PLC synchronized production by working fully integrated with coil unwinders, strip feeders, and loading robots.
• Motorized and Memorized Ram Adjustment: A system that can digitally adjust the ram (stroke) distance down to the millimeter without touching when different molds are attached and saves this measurement in its memory.
• Heavy-Duty Balance Pistons: Pneumatic balancing cylinders that zero out the load on the crank gear and brake pads by keeping the weight of the massive upper mold group suspended in the air.

Heavy Press Modernization: Save Your Idle Machines

The cost of a brand new 200-ton capacity press is a massive budget for any business. If you have an old-style mechanical (rigid clutch) 200-ton press lying in your factory that fails occupational safety laws, you can modernize it with Karmaksan Machine's expertise instead of selling it. As Turkey's most assertive press modernization expert, we practically rebuild your machine.

We completely cancel the old mechanical parts, grind the massive bearings with zero tolerance, and switch your machine to a brand new "Pneumatic Air Clutch" system. With the PLC control panel and hydraulic overload safety we add, your old H-Frame heavy press gains all the smart features of a brand new machine that just left the factory today.

To feel the unshakeable power of heavy industry on your production lines, prepare your factory for dark (unmanned) production in Industry 4.0 standards, and get advantageous price quotes directly from the manufacturer, you can visit our contact page. For your custom mold and tonnage projects, you can instantly start a technical discussion with our engineers via the WhatsApp support line in the bottom right corner of the page.