CN109175183B - Hybrid power hydraulic transmission system and method of large-scale swage hydraulic press - Google Patents
Hybrid power hydraulic transmission system and method of large-scale swage hydraulic press Download PDFInfo
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- CN109175183B CN109175183B CN201811202320.XA CN201811202320A CN109175183B CN 109175183 B CN109175183 B CN 109175183B CN 201811202320 A CN201811202320 A CN 201811202320A CN 109175183 B CN109175183 B CN 109175183B
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- 230000005540 biological transmission Effects 0.000 title claims abstract description 37
- 238000000034 method Methods 0.000 title claims abstract description 34
- 238000005242 forging Methods 0.000 claims abstract description 34
- 239000011159 matrix material Substances 0.000 claims abstract description 26
- 238000004519 manufacturing process Methods 0.000 claims abstract description 22
- 239000007788 liquid Substances 0.000 claims description 24
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 18
- 238000002955 isolation Methods 0.000 claims description 15
- 239000007789 gas Substances 0.000 claims description 12
- 229910052757 nitrogen Inorganic materials 0.000 claims description 9
- 230000004044 response Effects 0.000 claims description 7
- 238000001914 filtration Methods 0.000 claims description 6
- 238000006243 chemical reaction Methods 0.000 claims description 3
- 238000010438 heat treatment Methods 0.000 claims description 3
- 230000001502 supplementing effect Effects 0.000 claims description 3
- 238000001816 cooling Methods 0.000 claims description 2
- 239000003921 oil Substances 0.000 description 111
- 230000008569 process Effects 0.000 description 19
- 230000009365 direct transmission Effects 0.000 description 14
- 238000001125 extrusion Methods 0.000 description 14
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 9
- 239000002131 composite material Substances 0.000 description 8
- 238000011049 filling Methods 0.000 description 8
- 238000013461 design Methods 0.000 description 6
- 238000005265 energy consumption Methods 0.000 description 6
- 239000002184 metal Substances 0.000 description 4
- 238000005516 engineering process Methods 0.000 description 3
- 238000009434 installation Methods 0.000 description 3
- 238000011068 loading method Methods 0.000 description 3
- 239000004033 plastic Substances 0.000 description 3
- 230000009286 beneficial effect Effects 0.000 description 2
- 239000010720 hydraulic oil Substances 0.000 description 2
- 238000004080 punching Methods 0.000 description 2
- 238000009966 trimming Methods 0.000 description 2
- 229910052799 carbon Inorganic materials 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 230000001276 controlling effect Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000007599 discharging Methods 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000005086 pumping Methods 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 230000001360 synchronised effect Effects 0.000 description 1
- 238000010104 thermoplastic forming Methods 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J9/00—Forging presses
- B21J9/10—Drives for forging presses
- B21J9/12—Drives for forging presses operated by hydraulic or liquid pressure
- B21J9/16—Drives for forging presses operated by hydraulic or liquid pressure in conjunction with steam or gas power
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B30—PRESSES
- B30B—PRESSES IN GENERAL
- B30B15/00—Details of, or accessories for, presses; Auxiliary measures in connection with pressing
- B30B15/16—Control arrangements for fluid-driven presses
- B30B15/163—Control arrangements for fluid-driven presses for accumulator-driven presses
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- Fluid-Pressure Circuits (AREA)
- Press Drives And Press Lines (AREA)
Abstract
The invention discloses a hybrid power hydraulic transmission system and method of a large-scale forging hydraulic machine, wherein the hybrid power hydraulic transmission system comprises an ultrahigh-pressure plunger variable pump set, a medium-high pressure accumulator, a matrix type multi-output integrated control valve block, an accumulator control valve block, a low-pressure oil tank, a non-pressure oil tank, an inflation system, a circulating system and a main cylinder and auxiliary cylinder control valve block, wherein the main cylinder and the auxiliary cylinder control valve block are respectively connected with the ultrahigh-pressure plunger variable pump set, the accumulator control valve block and the medium-high pressure accumulator through pipelines and the matrix type multi-output integrated control valve block. On the premise of completely meeting the technological force energy parameters, the hybrid power hydraulic transmission system can supply oil to a plurality of hydraulic presses according to the technological load curve in different time periods in one technological cycle period, can greatly reduce the total installed power required by each hydraulic press to independently establish a pump station, effectively reduces the reactive power of a accumulator or less functional consumption, improves the operation efficiency, can obviously reduce the purchasing cost of the hydraulic system, and reduces the project investment and the production operation cost.
Description
Technical Field
The invention relates to a hybrid power hydraulic transmission system and a method of a large-scale forging hydraulic press, and belongs to the technical field of metal plastic forming hydraulic presses.
Background
The hydraulic drive pump station is a power source of a large-scale forging hydraulic press and is the most important technical heart of equipment. When the hydraulic machine works, huge force and working speed sent by the working cylinder of the hydraulic machine are transmitted by the hydraulic pump station. Therefore, the pressure energy, the flow rate and the power consumption of the hydraulic pump station must meet the characteristic requirements of different production processes and the economic requirements of equipment operation.
At present, the hydraulic transmission system adopted by the large-scale forging hydraulic press generally has the following two modes:
the traditional water pump-accumulator transmission system can only generate 90% of rated pressure when the pressure is large, the pressure adjustment is difficult, the stroke control precision of the press is poor, the pressurizing speed is difficult to automatically adjust, and the production process characteristics are poor; the pump has lower installed power, but the efficiency is lower than 74 percent, no matter the load, the pump consumes full power in each working stroke, the total efficiency is low, and the energy consumption is higher. For oversized die forging hydraulic presses, the area of the working cylinder needs to be increased or a supercharging technology is adopted due to the application limitation of an ultrahigh pressure large flow water pump and a high pressure accumulator.
The oil pump direct transmission system can continuously work under full pressure, the automatic control performance of the pressurizing speed is good, the stroke control precision of the press is high, the pump efficiency is more than 93%, the energy consumption is 30% lower than that of the water pump-accumulator, and the adaptability of the production process characteristics is good; however, the installed power of the pump is very high, for example, the number of main pumps of a 500MN die forging hydraulic press reaches 60 only with 42MPa pressure, the number of main pumps of an 800MN die forging hydraulic press reaches 68, and the pump station is provided with 30 ultrahigh-pressure superchargers, so that the pipeline system is complex, and the pump station is very large in construction. The installed power of the main pumps of the two hydraulic presses is 24000kW and 27000kW respectively. Such high installed power, low turn-on probability and low operating efficiency, result in increased project investment and increased production and operating costs.
Disclosure of Invention
In order to solve the problems, the invention discloses a hybrid power hydraulic transmission system and a hybrid power hydraulic transmission method of a large-scale hydraulic press for die forging, and provides a hybrid power hydraulic transmission system technology of oil pump direct transmission and accumulator flow and pressure dynamic compensation, and a hybrid power hydraulic transmission combined pump station for an oversized multi-directional double-acting precise extrusion forming hydraulic press is developed. The hydraulic press is used for ultra-large multi-directional double-acting precise extrusion forming hydraulic press, can be widely applied to multi-directional die extrusion, die forging, isothermal die forging, isobaric lower forming, equal forging ratio forming, precise forming, superplastic forming and other metal plastic flexible composite forming processes of complex and difficult-to-form products in marine engineering, ships, oil gas, chemical industry, aerospace, weapons and nuclear power industry, and realizes near-net forming of the parts. The specific technical scheme is as follows:
the hybrid power hydraulic transmission system of the large-scale hydraulic forging press comprises a plurality of ultrahigh pressure plunger variable pump sets, a plurality of medium-high pressure accumulators, a matrix type multi-output integrated control valve block, an accumulator control valve block, a low-pressure oil tank, a non-pressure oil tank, an inflation system, a circulation system and a plurality of main cylinder and auxiliary cylinder control valve blocks for a plurality of hydraulic presses.
The main cylinder and the auxiliary cylinder control valve block are respectively connected with the ultrahigh pressure plunger variable pump set, the accumulator control valve block and the medium-high pressure accumulator through pipelines and the matrix type multi-output integrated control valve block, and output pipelines of the main cylinder and the auxiliary cylinder control valve block are respectively connected to the main cylinder or the auxiliary cylinder of the controlled hydraulic machine.
The ultrahigh-pressure plunger variable pump set comprises a plurality of variable pumps, the low-pressure oil tank supplies oil to each variable pump and charges liquid for a main cylinder of each hydraulic machine, a one-way valve is arranged at an outlet of each variable pump, and each variable pump outlet is independently connected to a matrix type multi-output integrated control valve block;
the medium-high voltage accumulator comprises a plurality of oil tanks and gas tanks, an oil tank outlet pipeline is directly connected to an accumulator control valve block, and the accumulator control valve block controls the compensation flow output by the oil tank;
the matrix type multi-output integrated control valve block is used for controlling flow input and output of the ultrahigh-pressure plunger variable pump set and the medium-high-pressure accumulator;
the accumulator control valve block comprises a high-frequency response proportional valve, a reversing valve, a lowest liquid level valve, a pilot double-stage pressure overflow valve, a pressure reducing valve and a manual gate valve. The high-frequency response proportional valve controls the output of the maneuvering flow of the oil tank; the reversing valve controls the oil supplementing operation of the ultrahigh-pressure plunger variable pump set to the oil tank in a cycle period, so that the stored power is recovered; the lowest liquid level valve is responsible for safety control of the oil tank at the lowest oil level; the pilot double-stage pressure overflow valve controls the working pressure conversion of the oil tank; the pressure reducing valve maintains pressure oil of the oil tank as a pilot control oil source of the whole hydraulic system; the oil tank oil way is sequentially connected with the return cylinder of the corresponding main working cylinder through the switching of a plurality of manual gate valves, so that the die opening and return of the die can be manually realized under the accident power failure state;
the low-pressure oil tank is connected with the inflation system and the circulation system, the inflation system is used for filling or releasing the gas pressure in the low-pressure oil tank 5, and the circulation system is used for realizing the heating, cooling and filtering circulation of the low-pressure oil tank.
In the matrix type multi-output integrated control valve block, each column of isolation valves respectively provide an input flow passage for each variable pump and each accumulator, and each input flow passage is respectively provided with a pilot circulating overflow valve;
in the matrix type multi-output integrated control valve block, each horizontal row of isolation valves respectively provides an output flow passage for each independent main cylinder and auxiliary cylinder control valve block, and each output flow passage is respectively provided with a pipeline pressure relief valve, so that pipelines leading to each main cylinder and auxiliary cylinder control valve block and all variable pumps can be independently relieved;
each column of input runners is in communication with a corresponding row of output runners through isolation valves, each output runner being individually connected to a corresponding master cylinder and slave cylinder control valve block.
The hydraulic oil pump further comprises a non-pressure oil tank, wherein the non-pressure oil tank is used for collecting internal leakage oil of the ultra-high pressure plunger variable pump set, the main cylinder and the auxiliary cylinder control valve block, and clean oil is returned to the low-pressure oil tank after filtering.
The low-pressure oil tank is a pressure oil tank with the pressure of 0.3-0.5 MPa.
The medium-high voltage accumulator also comprises a PSA on-site nitrogen production system, and the PSA on-site nitrogen production system and the gas compressor are used for first pressurizing an oil tank and a gas tank of the medium-high voltage accumulator and storing power.
The hybrid power hydraulic transmission method of the large-scale forging hydraulic press is characterized in that when the working pressure is less than 25MPa and the speed is 25-30mm/s, the oil pump power of the ultra-high pressure plunger variable pump unit is directly transmitted; when the working pressure is more than 25MPa and less than 32MPa and the speed is 50-60mm/s, the power of the oil pump of the ultrahigh pressure plunger variable pump unit is directly transmitted, and the power is stored by the medium-high pressure accumulator for dynamic compensation; when the working pressure is more than 32MPa and less than 42MPa and the speed is 20-30mm/s, the oil pump power of the ultrahigh-pressure plunger variable pump unit is directly transmitted; the die forging working condition after the preform is directly transmitted by the oil pump power of the ultrahigh-pressure plunger variable pump unit 1, the dynamic compensation is carried out by matching with the stored power of the medium-high pressure accumulator, and the oil pump power of the ultrahigh-pressure plunger variable pump unit 1 is directly transmitted in the final forming stage; and each auxiliary cylinder of the No. 1 hydraulic machine and working cylinders of other hydraulic machines are directly driven by the oil pump power of the ultrahigh-pressure plunger variable pump unit.
The beneficial effects of the invention are as follows:
the invention is different from any existing oil pump direct transmission system or traditional water pump-accumulator transmission system, and has remarkable novelty, creativity and practicability.
The invention relates to a hybrid power combined pump station with direct transmission of an oil pump and dynamic compensation of flow and pressure of an accumulator, which is a system combining direct transmission of oil pump power and power transmission stored by the accumulator, and is an oil pump direct transmission system with dynamic compensation of power stored by the accumulator.
(1) According to the characteristics of the multidirectional double-acting composite extrusion process and the die forging process, the advantages of the existing transmission system are absorbed, the defects of the existing transmission system are avoided, on the premise that the process capacity parameters are completely met, the combined pump station can supply oil to a plurality of hydraulic machines according to the process load curve in different periods of time, the total installed power required by each hydraulic machine to independently establish the pump station can be greatly reduced, the reactive power or the less functional consumption of the accumulator can be effectively reduced, the operation efficiency is improved, the purchasing cost of the hydraulic system can be remarkably reduced, and the project investment and the production operation cost are reduced.
(2) When the liquid supply amount of the direct transmission of the pump accounts for about 50%, the flow requirement of 50% of the maximum working speed of each main cylinder can be met, and the flow requirement of the idle stroke movement of each main cylinder and the maximum working speed of all other cylinders can be completely met. The accumulator compensates the liquid supply amount to account for 50%, can be used for compensating the dynamic flow rate when the pressure is medium to the master cylinder, can be adjusted to work at two pressure levels of 25MPa and 32MPa according to the process requirement, and can also be used for oil pump-accumulator transmission.
(3) When the multidirectional double-acting composite extrusion process and the direct die forging process are adopted, the filling or upsetting load is less than 50% of the maximum load in 85% of the time period, and the hydraulic pump is directly driven to supply liquid into the cylinder together with the pump by using the 25MPa pressure level which is about 50% of the maximum working pressure of 42 MPa. The accumulator has high pressure boosting speed, the energy can be fully utilized, and simultaneously, 50% of liquid supply quantity is compensated for the main cylinder, so that the requirement of the maximum working speed is met. When the load pressure exceeds 25MPa, the accumulator stops supplying liquid, and the pump directly drives at a flow rate of 50% of the maximum working speed until the working is finished.
(4) When the pre-blank post-die forging process is adopted, the die is in contact with the blank, the upper pressure is fast, the forming time is shorter, and the 32MPa pressure level is used for directly driving the pump to supply liquid into the cylinder. The energy of the accumulator can be fully utilized, and meanwhile, 50% of liquid supply amount is compensated for the main cylinder, so that the maximum working speed requirement is met. When the load pressure exceeds 32MPa, the accumulator stops supplying liquid, and the pump directly drives at a flow rate of 50% of the maximum working speed until the working is finished.
Or when any working condition is permitted, the oil pump can be directly driven to carry out upsetting or filling extrusion at 50% of the maximum working speed, when the load pressure rises to 20MPa, the accumulator flow compensation is started until the load pressure exceeds the accumulator pressure, the accumulator stops supplying liquid, and the pump is directly driven at the flow of 50% of the maximum working speed until the working is finished. Thus, the accumulator energy is fully utilized and efficiency is improved.
It can be seen that the oil pump direct drive system using accumulator dynamic compensation is different from the traditional water pump-accumulator drive system which is operated at maximum pressure regardless of load size, and is also different from the oil pump direct drive system of maximum pressure and maximum flow rate, full power loader. The accumulator stores power only to compensate the insufficient flow of the oil pump in the middle-low pressure load stage, so as to meet the requirement of the specified working speed.
(5) Compared with the traditional independent and distributed pump head valve, the matrix type multi-output integrated valve block has the advantages that the pipeline of the whole transmission system is shortest, the pipe diameter is smaller, an isolation valve with a large diameter is not required to be arranged in the system, and the pressure impact during switching of the isolation valve can be effectively reduced; the matrix type multi-output integrated valve block can enable each working oil cylinder to share flow supply of each pump in different time periods, any pump in the system fails, and any other pump can replace work on line.
The invention directly leads to the realization of a brand new extra-large multidirectional die double-acting composite precise extrusion forming hydraulic machine. The hybrid power transmission principle and structure can be widely applied to various tonnage die forging hydraulic presses, multi-directional die extrusion hydraulic presses, multi-directional stamping hydraulic presses and the like, and can be used for various thermoplastic forming and isothermal forming processes. Thereby bringing a plurality of beneficial effects: from the technical point of view, the high-precision parts with branch tooth shapes and cavity complex integral structures in different directions can be formed, the metal deformation rate control is realized, the product performance and quality are improved, the production efficiency and the material utilization rate are greatly improved, the energy consumption is reduced, the low-carbon production is realized, and the cost is reduced; from the engineering perspective, the power resources are reasonably configured by closely combining the technical characteristics, the requirements of functions and performances of the hydraulic press are met, and the capacity and reactive power loss of the general assembly machine are greatly reduced, so that the basic cost of the capacity of a user power supply transformer and the energy consumption in production are reduced. The weight of the equipment is reduced, the occupied area and the pit depth of the equipment are reduced, the equipment foundation is simplified, the working area and the height space of a workshop are fully utilized, and the maintenance cost, the investment cost and the like are reduced.
Drawings
Figure 1 is a schematic diagram of the working principle of the invention,
figure 2 is a graph of simulated deformation resistance over time for a typical workpiece 5 1/8 "valve body multi-directional double-acting coextrusion process,
list of reference numerals: 1-ultrahigh pressure plunger variable pump set, 2-medium and high pressure accumulator, 3-matrix type multi-output integrated control valve block, 4-accumulator control valve block, 5-low pressure oil tank, 6-pressureless oil tank, 7-inflation system, 8-circulation system, 9-main cylinder and auxiliary cylinder control valve block, 10-pipeline, 11-check valve, 12-1-oil tank, 12-2-gas tank, 13-PSA on-site nitrogen making system, 14-isolation valve, 15-pilot circulation overflow valve, 16-pipeline relief valve, 17-high frequency response proportional valve, 18-reversing valve, 19-lowest liquid level valve, 20-pilot double-stage pressure overflow valve, 21-pressure reducing valve and 22-manual gate valve.
Detailed Description
The invention is further elucidated below in connection with the drawings and the detailed description. It should be understood that the following detailed description is merely illustrative of the invention and is not intended to limit the scope of the invention.
The main device of the hybrid hydraulic transmission system of the large-scale forging hydraulic press comprises: several ultrahigh pressure plunger variable pumps, several middle and high pressure accumulators, low pressure oil tank and pressureless oil tank, its circulation system, matrix type multiplexing output integrated control valve block, PSA site nitrogen-making system, etc. The devices are organically connected through a pipeline with proper flow velocity, so that a combined pump station which can meet the requirements of various metal plastic flexible composite forming processes such as multidirectional die extrusion, die forging, isothermal die forging, isobaric lower forming, equal forging ratio forming, precise forming, superplastic forming and the like and the sharing of a plurality of hydraulic presses such as a prefabricated blank, punching and trimming and the like can be directly driven by a pump, can be independently driven by an oil pump and an accumulator, and can be directly driven by the pump and can also be driven by a hybrid power of flow and pressure dynamic compensation of the accumulator.
The ultrahigh-pressure plunger variable pump of the hybrid power hydraulic transmission system of the large-scale forging hydraulic machine is a plurality of variable pumps, the working pressure is more than 42MPa, the output flow is more than 635L/min, and the low-pressure oil tank supplies oil for the ultrahigh-pressure plunger variable pump. The accumulator is a plurality of oil tanks and gas tanks, the working pressure can be adjusted between 25MPa and 32MPa according to the production process requirement, and the PSA on-site nitrogen production system charges the accumulator for the first time.
The maximum output flow of the variable pump and the maneuvering volume of the accumulator are determined by the driving conditions and the speed of each main working cylinder. When the working pressure is less than 25MPa and the speed is 25-30mm/s, the variable pump directly drives the variable pump; when the working pressure is less than 32MPa and the speed is 50-60mm/s, the variable pump directly drives and dynamically compensates the accumulator; when the working pressure is more than 32MPa and up to 42MPa and the speed is 20-30mm/s, the variable pump directly drives the variable pump; the die forging working condition after the preform is directly transmitted by a variable pump and dynamically compensated by a potential accumulator, and the final forming stage is directly transmitted by the variable pump; the main cylinder of the No. 1 hydraulic machine, each auxiliary cylinder and the main cylinder of other hydraulic machines are respectively connected with the main cylinder and the auxiliary cylinder control valve block through pipelines and are directly driven by the variable pump.
The accumulator can also be used as a pilot control oil source of the whole hydraulic system, and comprises pilot control of each ultrahigh-pressure plunger variable pump group, auxiliary pump, main cylinder, auxiliary cylinder control valve block and accumulator control valve block; meanwhile, under the accident power failure state, the die opening function and the return function of the die can be realized.
The working pressure of the low-pressure oil tank is 0.3-0.5MPa, and the hydraulic oil tank has the functions of filling liquid for idle stroke movement of each main working cylinder of each hydraulic machine and supplying oil for the ultrahigh-pressure plunger variable pump set and the auxiliary pump. When the main working cylinder is filled with liquid, lower pressure is adopted, and when the ultrahigh pressure plunger variable pump set and the auxiliary pump are used for supplying oil, the pressure requirement of the oil suction cavity suitable for different pumps is adopted, and the oil is required to be subjected to precise filtration through a circulating system and is suitable for the oil temperature.
The non-pressure oil tank is used for oil return of the pilot control system, and the normal leaked oil in the hydraulic system is collected, filtered and recycled back to the low-pressure oil tank.
The matrix type multi-output integrated control valve block consists of a pump head multi-output integrated valve block and an accumulator output control valve block.
The pump head multi-output integrated valve block can integrate the input and output of the total flow of a plurality of variable pumps and the motor flow of the accumulator. The high-pressure outlet oil of each variable pump and the output oil of the accumulator motor flow are respectively input into the integrated valve block through a one-way valve. Each input flow passage in the integrated valve block is provided with a pilot circulation overflow valve and a plurality of isolation valves. The total input flow channel of the integrated valve block is equal to the sum of the number of variable pump and the input flow channel of the accumulator. The total output flow passage of the integrated valve block is determined according to the number of main working cylinders which are required to be driven, and one output flow passage is generally arranged for each independent main working cylinder, and if the two main working cylinders can be mutually compatible in one cycle period, one output flow passage can be arranged for more than two main working cylinders. Each output flow passage is communicated with the input flow passage by an isolation valve and is connected with a control valve of each main working cylinder. Each output runner is provided with a pipeline pressure relief valve respectively.
An accumulator output control valve block is arranged behind the manual gate valve of the accumulator and consists of an electric control double-pressure regulating overflow valve, a lowest liquid level valve, a proportional reversing valve, a high-pressure liquid filling valve, a pressure reducing valve and the like. The oil outlet pipeline of the proportional reversing valve is led to the pump head multi-output integrated valve block.
According to the control requirement of each main working cylinder, the matrix type multi-output integrated valve block can enable each output port to share the flow supply of each pump in different time periods through the isolation valve. That is, each master cylinder can share the oil supply of all pumps, and can obtain the oil supply of a single pump, a double pump and a plurality of pumps, and can obtain the flow supply of all pumps if necessary. That is, either main pump and accumulator may provide flow to either main cylinder.
The arrangement of the number of the high-pressure outlet channels not only considers the independent driving requirement of different working conditions of the main working cylinders of each hydraulic machine, but also considers the combined operation working conditions of each main working cylinder. For example, for the hydraulic press 1#, the functions of pressure maintaining, extrusion, perforation, ejection (or perforation), die forging, isothermal die forging, forging pressure grading, movable beam deviation correcting and leveling and synchronous control of the master cylinder 1 or the master cylinder 2 after die assembly can be realized.
The hybrid power hydraulic transmission combined pump station for directly transmitting the oil pump and dynamically compensating the flow and the pressure of the accumulator, as shown in figure 1, comprises a plurality of ultrahigh pressure plunger variable pump sets 1, a plurality of medium-high pressure accumulators 2, a PSA on-site nitrogen production system 13, a matrix type multi-output integrated control valve block 3, an accumulator control valve block 4, a low pressure oil tank 5, a non-pressure oil tank 6, an inflation system 7, a circulation system 8 and a main working oil cylinder 9. The devices are connected by a pipe 10 of suitable flow rate as shown in schematic form.
1) Ultrahigh-pressure plunger variable pump set 1
According to the ultrahigh-pressure plunger variable pump set 1, the variable pumps with the least number are configured according to the process conditions and deformation process curves of direct transmission of the pumps, the working pressure of the variable pumps is more than 42MPa, the output flow is more than 635L/min, high-frequency response proportional volume variable control is adopted, and the low-pressure oil tank 5 supplies oil for the variable pumps. Each variable pump outlet is provided with a one-way valve 11, and each one is independently connected to the matrix type multi-output integrated control valve block 3.
Compared with the traditional design method that the variable pump direct transmission system is configured according to the maximum flow and the maximum pressure required by the maximum working speed of the process, the number of the variable pumps is greatly reduced, the installed power can be reduced by more than 50%, the reactive power loss and the air circulation power loss are effectively reduced, and the heating of the system is reduced. The outlet pipelines of the variable pump are independently arranged, the pipe diameter is small, the liquid Rong Xiao is pressurized quickly, and the pressure release impact is small.
2) Medium-high voltage accumulator 2 and PSA on-site nitrogen production system 13
The high-pressure accumulator 2 in the invention determines maneuvering volume and flow rate during medium-high pressure dynamic compensation according to process conditions and deformation process curves, and is provided with a plurality of oil tanks and gas tanks 12. The working pressure can be adjusted between 25MPa and 32MPa, and the PSA site nitrogen making system 13 charges the pressure for the first time and stores power. The tank outlet pipe is directly connected to the accumulator control valve block 4 and the compensated flow output by the tank is controlled by it.
Compared with the traditional design method that the accumulator provides maneuvering volume completely by the traditional water pump-accumulator transmission system which has no relation with the load size and always outputs the maximum pressure and the maximum flow, the number of the required tanks is greatly reduced, the reactive power of the accumulator or the less functional consumption of the accumulator can be effectively reduced, and the transmission efficiency is improved.
3) Matrix type multi-output integrated control valve block 3
The matrix type multi-output integrated control valve block 3 integrates flow input and output of a plurality of ultrahigh-pressure plunger variable pump sets 1 and medium-high-pressure accumulators 2.
The longitudinal columns of the matrix are input flow channels of the motor flow of each variable pump 1 and each accumulator 2, and the total number of the input flow channels is equal to the sum of the number of the variable pumps 1 and the input flow channels of the accumulator 2. The horizontal rows of the matrix 1 are output channels for providing flow to each independent main working cylinder control valve block 9, the total number of the output channels is determined according to the number of main working cylinders which are required to be driven, and if the two or more main working cylinders can be mutually compatible in one cycle period, one output channel can be arranged for more than two main working cylinders.
Each column of input flow channels is respectively communicated with m transverse output flow channels through m isolation valves 14; each output flow passage is individually connected to m master cylinder control valve blocks 9.
Each column of input flow channels is always provided with a pilot circulation overflow valve 15, which can be used as a pump head safety valve or a pump load empty circulation; each output flow passage is provided with a pipeline relief valve 16, so that the pipeline leading to each master cylinder and all pumps can be independently relieved.
Compared with the traditional design method that each pump is provided with an independent and distributed pump head valve group, the pressure relief impact of the pump head circulating valve is avoided; each pump can be independently pressed and debugged on a pump station, and the switching state of an oil inlet valve of each main valve block is not needed to be worried; the pump station or the main valve block does not need to be provided with an isolation valve with a large diameter, so that the pressure impact during the switching of the isolation valve can be effectively reduced; the number of connecting pipelines and joints between the pump and the master cylinder control valve block is greatly reduced, so that the pipeline of the whole transmission system is shortest, the pipe diameter is smaller, and leakage links possibly caused by the pipeline are reduced; the oil can be distributed directly to the different master cylinders at the pumping station, and all pumps can serve any one master cylinder. The flow supply of each pump can be shared by each working cylinder in different time periods, any pump in the system fails, any other pump can replace the working on line, and the problem that oil sources do not exist after one pump fails is avoided.
4) Accumulator control valve block 4
The accumulator control valve block 4 controls the output of the maneuvering flow of the oil tank 12-1 by the high-frequency response proportional valve 17; the reversing valve 18 controls the oil supplementing operation of the ultrahigh-pressure plunger variable pump set 1 to the oil tank 12-1 in one cycle period so as to restore the stored power; the lowest liquid level valve 19 is responsible for the safety control of the oil tank 12-1 at the lowest oil level; the pilot double-stage pressure relief valve 20 controls the working pressure conversion of the oil tank 12-1; the pressure oil in the oil tank 12-1 can be used as a pilot control oil source of the whole hydraulic system through the pressure reducing valve 21; the oil way of the oil tank 12-1 is respectively connected with the return cylinder of the main working cylinder through the switching of a plurality of manual gate valves 22, and the die opening and the return stroke of the die can be manually realized under the accident power failure state.
Compared with the traditional water pump-accumulator transmission system, the flow output of the oil tank 12-1 can be accurately controlled, the pressure regulation can be realized, the pressure impact can be eliminated, the hydraulic system can be used as a pilot control oil source of the hydraulic system, the hydraulic system comprises pilot control of each ultrahigh-pressure plunger variable pump group, auxiliary pump, main cylinder and auxiliary cylinder control valve block and accumulator control valve block, and the configuration and the installation power of the independent control pump are reduced.
5) Low-pressure tank 5 and non-pressure tank 6
The low-pressure oil tank 5 is a 0.3-0.5MPa pressure oil tank, has the function of filling liquid to the low pressure of each main working cylinder, and also has the function of providing low-pressure oil for each ultra-high pressure pump. The tank is heated, cooled and filtered by a circulation system 8 by filling or discharging the tank with gas pressure by an inflation system 7. The pressureless oil tank 6 is connected with and collects the oil return of the pilot control system of the ultrahigh pressure plunger variable pump group, the auxiliary pump, the main cylinder, the auxiliary cylinder control valve block and the accumulator control valve block through pipelines, and normally leaks oil in the pump and the system, and clean oil is returned to the low-pressure oil tank 5 after filtering so as to keep the balance of the oil liquid amount of the system.
Compared with the traditional design method of the oil pump direct transmission system, the method does not adopt a centrifugal pump with large flow, high power and low efficiency as the main working cylinder for filling liquid, does not adopt a screw pump with large flow and high power for providing low-pressure oil for the ultra-high pressure pump, greatly reduces the installed power, reduces the running power loss and saves energy.
6) The embodiment of the invention develops a hybrid power hydraulic transmission combined pump station with oil pump direct transmission and accumulator flow and pressure dynamic compensation, which is used for driving three devices of a 350MN seven-axis numerical control multi-directional die double-acting composite precision extrusion forming hydraulic machine, a 30MN blank-making hydraulic machine and a 20MN punching and trimming hydraulic machine. Compared with the traditional design, the project investment is reduced, and the production cost is reduced remarkably: the total power of the installation is reduced to 6081.5kW from the original design 19253kW, the installation capacity of the transformer is reduced to 8000kVA from 20000kVA, the basic cost of the capacity is reduced by 637 ten thousand yuan each year, and the energy consumption is reduced by 1063 ten thousand yuan each year; the manufacturing cost of the transformer substation, the manufacturing cost of the equipment foundation and the hydraulic electric control purchasing cost can be reduced by more than half.
FIG. 2 is a graph of simulated deformation resistance over time for a typical workpiece 5 1/8' valve body multi-directional double-acting composite extrusion process, showing that in one loading cycle period, the loading time is less than 15%, the unloading time is greater than 85%, and the maximum deformation resistance is only 15% of the loading time, accounting for 2% of the entire cycle period. Even for the post-preform swage condition, the average deformation resistance is less than 50% of nominal force, with a load time of much less than 10%.
The working cycle period of the multidirectional double-acting extrusion or die forging working condition is longer, the working stroke is smaller, the load rate is lower, and if the pump direct transmission system is designed, the installed power is high; if the number of the water pumps is determined according to the average value of the required flow in one working cycle according to the traditional water pump-accumulator transmission system, the number of the required pumps is small, and the requirements of the working speeds of the auxiliary cylinders of the 350MN hydraulic machine, the 30MN hydraulic machine and the 20MN hydraulic machine cylinders in one production line cannot be met. Moreover, the highest pressure of the accumulator is 32MPa, and the requirement of the pressure of the 350MN hydraulic press system for 42MPa cannot be met.
Therefore, according to the characteristics of the multidirectional double-acting composite extrusion process and the transmission requirements of a plurality of hydraulic presses, a hybrid power combined pump station is formed by adopting a mode of combining direct transmission of an oil pump and dynamic compensation of an accumulator, so that the advantages of direct transmission of the oil pump in terms of power consumption, ultrahigh pressure, speed control, efficiency and the like can be fully exerted, meanwhile, the technology of dynamically compensating flow in a medium-high pressure stage by utilizing the accumulator can be utilized, the power can be fully utilized, the energy consumption is relatively low, the total power of a machine is reduced to the greatest extent, the energy is saved, the project investment is obviously reduced, and the production and operation costs are reduced.
With the above-described preferred embodiments according to the present invention as an illustration, the above-described descriptions can be used by persons skilled in the relevant art to make various changes and modifications without departing from the scope of the technical idea of the present invention. The technical scope of the present invention is not limited to the description, but must be determined according to the scope of claims.
Claims (4)
1. The hybrid power hydraulic transmission method of the large-scale forging hydraulic press is characterized in that a hybrid power hydraulic transmission system of the large-scale forging hydraulic press is adopted, and when the working pressure is less than 25MPa and the speed is 25-30mm/s, the oil pump power of an ultrahigh-pressure plunger variable pump set (1) is directly transmitted; when the working pressure is more than 25MPa and less than 32MPa and the speed is 50-60mm/s, the power of the oil pump is directly transmitted by the ultrahigh pressure plunger variable pump group (1), and the power stored by the medium-high pressure accumulator (2) is dynamically compensated; when the working pressure is more than 32MPa and less than 42MPa and the speed is 20-30mm/s, the oil pump power of the ultrahigh-pressure plunger variable pump set (1) is directly transmitted; the die forging working condition after the preform is directly transmitted by the oil pump power of the ultrahigh-pressure plunger variable pump unit (1), the dynamic compensation is carried out by the power stored by the medium-high-pressure accumulator (2), and the oil pump power of the ultrahigh-pressure plunger variable pump unit (1) is directly transmitted in the final forming stage; each auxiliary cylinder of one hydraulic machine and the main cylinder of other hydraulic machines are directly driven by the oil pump power of the ultrahigh-pressure plunger variable pump unit (1);
the hybrid power hydraulic transmission system of the large-scale hydraulic forging press comprises a plurality of ultrahigh pressure plunger variable pump sets (1), a plurality of medium-high pressure accumulators (2), a matrix type multi-output integrated control valve block (3), accumulator control valve blocks (4), a low-pressure oil tank (5), a non-pressure oil tank (6), an inflation system (7), a circulation system (8) and a plurality of main cylinder and auxiliary cylinder control valve blocks (9) of a plurality of hydraulic presses,
the main cylinder and the auxiliary cylinder control valve block (9) are respectively connected with the ultrahigh-pressure plunger variable pump set (1), the accumulator control valve block (4) and the medium-high pressure accumulator (2) through a pipeline (10) and a matrix type multiplexing output integrated control valve block (3), the output pipelines of the main cylinder and the auxiliary cylinder control valve block (9) are respectively connected to the main cylinder or the auxiliary cylinder of the controlled hydraulic machine,
the ultrahigh-pressure plunger variable pump set (1) comprises a plurality of variable pumps, the low-pressure oil tank (5) supplies oil to each variable pump and charges the main cylinder of each hydraulic machine, a one-way valve (11) is arranged at the outlet of each variable pump, and each variable pump is independently connected to the matrix type multi-output integrated control valve block (3);
the medium-high pressure accumulator (2) comprises a plurality of oil tanks (12-1) and gas tanks (12-2), an oil tank outlet pipeline is directly connected to an accumulator control valve block (4), and the accumulator control valve block (4) controls the compensation flow output by the oil tanks;
the matrix type multi-output integrated control valve block (3) is used for controlling the flow input and output of the ultrahigh-pressure plunger variable pump set (1) and the medium-high-pressure accumulator (2);
the accumulator control valve block (4) comprises a high-frequency response proportional valve (17), a reversing valve (18), a lowest liquid level valve (19), a pilot double-stage pressure overflow valve (20), a pressure reducing valve (21) and a manual gate valve (22), wherein the high-frequency response proportional valve (17) controls the output of the maneuvering flow of the oil tank (12-1); the reversing valve (18) controls the oil supplementing operation of the ultrahigh-pressure plunger variable pump set (1) to the oil tank (12-1) in a cycle period so as to restore the stored power; the lowest liquid level valve (19) is responsible for safety control of the oil tank (12-1) at the lowest oil level; the pilot double-stage pressure relief valve (20) controls the working pressure conversion of the oil tank (12-1); the pressure reducing valve (21) maintains the pressure oil of the oil tank (12-1) as a pilot control oil source of the whole hydraulic system; the oil way of the oil tank (12-1) is sequentially connected with the return cylinder of the corresponding main working cylinder through the switching of a plurality of manual gate valves (22), so that the die opening and return of the die can be manually realized under the accident power failure state;
the low-pressure oil tank (5) is connected with the inflation system (7) and the circulation system (8), the gas pressure in the low-pressure oil tank (5) is filled or released through the inflation system (7), and the circulation system (8) is used for realizing the heating, cooling and filtering circulation of the low-pressure oil tank (5);
the non-pressure oil tank (6) is used for collecting oil leakage in the ultrahigh-pressure plunger variable pump set (1) and the main cylinder and auxiliary cylinder control valve block (9), and clean oil is returned to the low-pressure oil tank (5) after filtering.
2. The hybrid hydraulic transmission method of a large-scale hydraulic forging press according to claim 1, wherein in the matrix type multi-output integrated control valve block (3), each column of isolation valves (14) respectively provide an input flow passage for each variable pump and each medium-high pressure accumulator (2), and each input flow passage is respectively provided with a pilot circulation overflow valve (15);
in the matrix type multi-output integrated control valve block (3), each horizontal row of isolation valves (14) respectively provide output flow passages of flow for each independent main cylinder and auxiliary cylinder control valve block (9), and each output flow passage is respectively provided with a pipeline relief valve (16) so that pipelines leading to each main cylinder and auxiliary cylinder control valve block (9) and all variable pumps can be independently relieved;
each column of input flow channels is communicated with a corresponding row of output flow channels through isolation valves (14), and each channel of output flow channels is individually connected to a corresponding main cylinder and auxiliary cylinder control valve block (9).
3. The hybrid hydraulic transmission method of a large-scale hydraulic forging press according to claim 1, wherein the low-pressure oil tank (5) is a pressure oil tank of 0.3-0.5 MPa.
4. The hybrid hydraulic transmission method of a large-scale hydraulic swage press according to claim 1, wherein the medium-high pressure accumulator (2) further comprises a PSA site nitrogen production system (13), and the PSA site nitrogen production system (13) charges the oil tank (12-1) and the gas tank (12-2) of the medium-high pressure accumulator (2) for the first time and stores power.
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| CN110918853B (en) * | 2019-12-07 | 2021-09-03 | 南京宏擎精密材料科技有限公司 | Energy-saving die forging hydraulic press and using method thereof |
| CN113442486A (en) * | 2021-06-29 | 2021-09-28 | 扬州迈拓机械科技有限公司 | Deformation compensation device and hydraulic machine |
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