An automatic pressure relief system and method for a cubic press

Abstract

The application relates to the technical field of superhard material synthesis equipment control, and discloses a cubic press automatic pressure relief system and method, which comprises a central control unit, wherein the central control unit is electrically connected with a UPS module, a pressure sensor and a stepping motor driving module; the stepping motor driving module is electrically connected with a pressure relief execution mechanism; the pressure relief execution mechanism comprises a pressure relief valve and a stepping motor, and the stepping motor is in transmission connection with a valve core of the pressure relief valve; wherein the pressure sensor collects hydraulic system pressure in real time and feeds back to the central control unit, forming pressure closed-loop control; the application can overcome the defects of the prior art, such as unstable three-stage pressure relief, high energy consumption, manual power failure emergency, slow response, low control precision, poor safety and the like, so as to realize normal working condition accurate pressure relief, power failure instant fast, stable and controllable automatic pressure relief, and guarantee diamond synthesis quality and equipment safety.

Description

Technical Field

[0001] This invention relates to the field of control technology for superhard material synthesis equipment, and in particular to an automatic pressure relief system and method for a six-sided top press. Background Technology

[0002] The six-sided pressure press is the core equipment for the synthesis of diamonds. It transforms carbon materials into diamonds through a high-temperature, high-pressure environment. The pressure stability of the hydraulic system directly determines the diamond yield and production safety. Existing pressure relief technologies have two major drawbacks: The conventional three-stage depressurization process curve fluctuates greatly and has poor stability. It requires frequent start-ups of the booster pump, resulting in high energy consumption and severely restricting the improvement of diamond crystal yield. In the event of a sudden, unplanned power outage, the hydraulic system loses power and becomes uncontrollable. The industry commonly employs manual emergency pressure relief, relying on operators to rush to the scene and manually rotate the handwheel of the pressure relief valve or operate the manual hydraulic pump to release pressure. However, manual emergency pressure relief has the following significant drawbacks: Delayed response to power outages and prolonged uncontrollable pressure can easily lead to pressure imbalance in the synthesis chamber, raw material spoilage, and equipment damage. Manual operation results in poor consistency, and the decompression curve varies from person to person, which disrupts process repeatability and affects product quality stability. Manual operation under high pressure conditions poses safety hazards such as mechanical injury and pressure loss impact. The level of automation and digitalization is low, there are no data records or abnormal alarms, and it is impossible to connect to the factory's intelligent management system. Summary of the Invention

[0003] The purpose of this invention is to provide an automatic pressure relief system and method for a six-sided top press, which can overcome the defects of the existing technology such as unstable three-stage pressure relief, high energy consumption, reliance on manual emergency response during power outages, slow response, low control precision, and poor safety. It can achieve accurate pressure relief under normal working conditions and rapid, stable, and controllable automatic pressure relief during power outages, thus ensuring the quality of diamond synthesis and equipment safety.

[0004] The present invention adopts the following technical solution: An automatic pressure relief system for a six-sided top press includes a central control unit, which is electrically connected to a UPS module, a pressure sensor, and a stepper motor drive module. The stepper motor drive module is electrically connected to a pressure relief actuator. The pressure relief actuator includes a pressure relief valve and a stepper motor, with the stepper motor and the valve core of the pressure relief valve being drivenly connected. The pressure sensor collects hydraulic system pressure in real time and feeds it back to the central control unit, forming a pressure closed-loop control. When the main power supply is interrupted, the UPS module supplies power to the system. Based on this power supply status and the pressure signal fed back by the pressure sensor, the central control unit controls the stepper motor through the stepper motor drive module, thereby controlling the pressure relief valve to perform automatic pressure relief.

[0005] Preferably, the system further includes an audible and visual alarm module and a data storage unit, both of which are electrically connected to the central control unit.

[0006] Preferably, the audible and visual alarm module consists of a warning light and a buzzer; the data storage unit uses non-volatile flash memory.

[0007] Preferably, the stepper motor output shaft is directly connected to the pressure relief valve core via a rigid connecting shaft.

[0008] Preferably, the UPS module is a backup uninterruptible power supply.

[0009] Preferably, the stepper motor drive module is a high-microstepping stepper driver.

[0010] An automatic pressure relief method for a six-sided top press, based on an automatic pressure relief system for a six-sided top press, includes the following steps: 1) Real-time monitoring of main power supply voltage and hydraulic system pressure; 2) Under normal operating conditions, the stepper motor drives the pressure relief valve to precisely relieve pressure according to the preset process curve; 3) When a main power supply interruption is detected, switch to UPS power supply; 4) Control the stepper motor to drive the pressure relief valve to perform closed-loop pressure relief according to the emergency pressure relief curve; 5) Once the pressure drops to the safe threshold, lock the valve position to complete the emergency pressure relief.

[0011] Preferably, in step 4), the depressurization rate is adaptively matched according to the synthesis process stage.

[0012] Preferably, the emergency depressurization process simultaneously triggers an audible and visual alarm and records the depressurization data.

[0013] Compared with the prior art, the beneficial effects of the present invention are as follows: First, the present invention can improve product quality: stabilize the depressurization curve, eliminate artificial randomness, reduce the synthesis failure rate caused by power outages, and improve the diamond crystal yield and production stability.

[0014] Secondly, this invention offers rapid response and high safety: millisecond-level power outage response, far faster than manual on-site arrival time; it also avoids personnel operating in hazardous environments, improving equipment reliability; furthermore, it achieves full automation of the depressurization process, with status monitoring and anomaly alarm functions, providing fundamental data support for the intelligent transformation of workshops. In addition, it eliminates the need for frequent booster pump starts, reducing power consumption; it reduces reliance on skilled workers and training costs, minimizing human error; and closed-loop regulation ensures a high degree of overlap between the actual curve and the preset curve, resulting in excellent process repeatability. Attached Figure Description

[0015] Figure 1 This is the control flowchart of the present invention. Detailed Implementation

[0016] The present invention will now be described clearly and completely with reference to the accompanying drawings and embodiments: like Figure 1 As shown, the automatic pressure relief system for a six-sided top press according to the present invention includes a central control unit, a UPS module, a stepper motor drive module, a pressure sensor, a pressure relief actuator, an audible and visual alarm module, and a data storage unit. The central control unit is electrically connected to the UPS module, the stepper motor drive module, the pressure sensor, the audible and visual alarm module, and the data storage unit. The stepper motor drive module is electrically connected to the pressure relief actuator, which includes a stepper motor and a pressure relief valve, with the stepper motor and the valve core of the pressure relief valve rigidly directly connected. The UPS module provides uninterrupted power to the entire control system and actuator when the main power supply is interrupted. The pressure sensor collects the hydraulic system pressure in real time and feeds it back to the central control unit, forming a pressure closed-loop control to ensure that the actual pressure relief curve coincides with the preset curve.

[0017] Specifically, the central control unit adopts an industrial-grade MCU main control board, with built-in high-precision AD sampling, pulse output, power failure detection, and serial communication units. It can collect data in real time on: main power supply voltage, hydraulic system pressure, and motor operating status. It also outputs in real time: stepper motor drive pulses, direction signals, alarm signals, valve locking signals, and stored control signals. It has a built-in adaptive pressure relief control algorithm that can correct the valve core opening in real time based on pressure feedback, ensuring a high degree of overlap in the pressure relief curves. It has a rapid power failure trigger capability, entering the emergency procedure ≤10ms after detecting a main power failure.

[0018] The UPS uninterruptible power supply module adopts a standby industrial UPS, with an input of AC220V and an output of DC24V / 12V required by the system. It has a runtime of at least 5 minutes, capable of completing a full emergency depressurization process. When the mains power is normal: it supplies power to the system and automatically float-charges the battery. When the mains power is interrupted: it seamlessly switches to battery power in milliseconds, ensuring uninterrupted control, drive, and sampling. Simultaneously, the module has voltage anomaly detection and fault feedback functions, uploading the status to the central control unit in real time.

[0019] The stepper motor drive module uses a high-microstepping stepper driver with a microstepping accuracy of ≥128 and a positioning accuracy of ±0.1°. It receives pulse and direction signals from the central control unit and drives a high-torque stepper motor, providing torque protection, position feedback, and fault alarm signals. It also communicates bidirectionally with the central control unit to achieve full closed-loop control of motor start / stop, speed adjustment, positioning, and locking.

[0020] The pressure sensor employs a high-precision hydraulic pressure sensor, with a measurement range covering the rated working pressure of the six-sided top press. It outputs a standard signal: 4-20mA or 0-10V, which is connected to the AD interface of the central control unit. The sampling frequency is ≥100Hz, reflecting system pressure changes in real time. The pressure sensor and the central control unit form a closed-loop feedback, ensuring that the actual pressure relief curve strictly tracks the preset curve.

[0021] The pressure relief actuator consists of a stepper motor and a dedicated hydraulic pressure relief valve. The stepper motor output shaft is directly connected to the valve core of the pressure relief valve via a rigid connecting shaft without any clearance. The motor rotation angle is directly equivalent to the valve core opening, which is proportional to the pressure relief flow rate. The valve core movement is smooth and shock-free, enabling linear pressure relief, segmented pressure relief, and non-linear adaptive pressure relief. The pressure relief actuator has a mechanical locking function, maintaining the valve core position unchanged after the pressure drops to a safe threshold.

[0022] The audible and visual alarm module consists of an alarm light and a buzzer. Triggering conditions include mains power failure, abnormal pressure, motor malfunction, and excessive pressure relief. The alarm signal is directly driven by the central control unit, providing continuous audible and visual alerts until manual confirmation is received.

[0023] The data storage unit uses non-volatile flash memory, ensuring data integrity even in the event of power failure. Recorded data includes: power outage time, power restoration time, pressure relief curve, pressure data, motor operation, and fault codes. Historical data can be read and exported, and the system can be integrated with factory intelligent management systems.

[0024] An automatic pressure relief method for a six-sided top press, based on the aforementioned system, includes two complete processes: normal process pressure relief and emergency pressure relief in the event of a power outage. Specifically, it includes: 1) Real-time status monitoring central control unit continuously executes The system collects the main power supply voltage to determine if it is in a normal power supply state. It also collects the hydraulic system pressure for closed-loop control and safety assessment. The system monitors the stepper motor position, drive status, and UPS operating status. All signals are sampled at a frequency ≥100Hz to ensure fast response and no lag.

[0025] 2) Automatic pressure relief under normal operating conditions After the synthesis process is completed, the system performs precise process depressurization: the central control unit receives the synthesis end command, reads the preset depressurization curve (linear / piecewise / nonlinear) corresponding to the current process, calculates the stepper motor speed, angle, and running time according to the curve, and outputs pulses to drive the stepper motor, causing the depressurization valve to open smoothly.

[0026] The pressure sensor provides real-time pressure feedback, and the central control unit performs PID closed-loop regulation: if the pressure drops too quickly, the valve opening is reduced; if the pressure drops too slowly, the valve opening is increased. Once the pressure drops to 0 MPa, the control motor resets, the pressure relief valve closes, and the entire normal pressure relief process is completed without impact or overshoot, ensuring the stability of the diamond crystal structure.

[0027] 3) Power outage detection and UPS power supply switching In the event of a sudden power outage: The central control unit detects the main power supply interruption within ≤10ms. It immediately triggers a seamless UPS power switch to ensure uninterrupted power supply throughout the system. It saves the current process status, pressure value, and motor position, and enters emergency pressure relief mode.

[0028] 4) Emergency closed-loop automatic pressure relief (including adaptive rate) The system automatically matches the optimal depressurization rate based on the current stage of the synthesis process: High-temperature and high-pressure synthesis section: Low-speed depressurization is adopted to avoid rupture of the cavity due to pressure loss; Insulation and pressure holding section: adopts medium-speed pressure relief; End of process: High-speed depressurization is adopted.

[0029] The central control unit outputs pulses according to the emergency pressure relief curve, driving a stepper motor to precisely open the valve core. Pressure feedback is provided in real time, and the opening degree is dynamically adjusted to achieve smooth, shock-free, and controllable pressure relief.

[0030] 5) The valve locks after the pressure reaches the target. When the pressure drops to a safe threshold (e.g., ≤10MPa), the motor stops operating; a locking signal is output to maintain the valve core position, preventing pressure rebound, malfunction, or accidental pressure increase. The locked state remains until power is restored and manual confirmation is received.

[0031] The entire emergency pressure relief process, including audible and visual alarms and data recording, is executed synchronously: The audible and visual alarms are activated to alert on-site personnel that the equipment is in a power outage emergency state. The time of power outage, the entire pressure process, the pressure relief curve, and motor actions are completely written to the storage unit. This supports post-event data traceability, process analysis, and fault diagnosis. Upon power restoration and manual reset: After mains power is restored: the system keeps the valves locked and does not automatically reset. It awaits on-site inspection and manual confirmation of reset by the operator. After confirming safety, the lock is released, the motor resets to its initial position, and the system returns to normal standby.

Claims

1. An automatic pressure relief system for a six-sided top press, characterized in that: The system includes a central control unit electrically connected to a UPS module, a pressure sensor, and a stepper motor drive module. The stepper motor drive module is electrically connected to a pressure relief actuator. The pressure relief actuator includes a pressure relief valve and a stepper motor, with the stepper motor and the valve core of the pressure relief valve being driven together. The pressure sensor collects the hydraulic system pressure in real time and feeds it back to the central control unit, forming a pressure closed-loop control. When the main power supply is interrupted, the UPS module supplies power to the system. Based on the power supply status and the pressure signal fed back by the pressure sensor, the central control unit controls the stepper motor through the stepper motor drive module, thereby controlling the pressure relief valve to automatically relieve pressure.

2. The automatic pressure relief system for a six-sided top press according to claim 1, characterized in that: It also includes an audible and visual alarm module and a data storage unit, both of which are electrically connected to the central control unit.

3. The automatic pressure relief system for a six-sided top press according to claim 2, characterized in that: The aforementioned audible and visual alarm module consists of a warning light and a buzzer; the aforementioned data storage unit uses non-volatile flash memory.

4. The automatic pressure relief system for a six-sided top press according to claim 1, characterized in that: The output shaft of the stepper motor is directly connected to the valve core of the pressure relief valve via a rigid connecting shaft.

5. The automatic pressure relief system for a six-sided top press according to claim 1, characterized in that: The UPS module is a backup uninterruptible power supply.

6. The automatic pressure relief system for a six-sided top press according to claim 1, characterized in that: The stepper motor drive module is a high-microstepping stepper driver.

7. An automatic pressure relief method for a six-sided top press, implemented based on the system described in any one of claims 1-6, characterized in that, Includes the following steps: 1) Real-time monitoring of main power supply voltage and hydraulic system pressure; 2) Under normal operating conditions, the stepper motor drives the pressure relief valve to precisely relieve pressure according to the preset process curve; 3) When a main power supply interruption is detected, switch to UPS power supply; 4) Control the stepper motor to drive the pressure relief valve to perform closed-loop pressure relief according to the emergency pressure relief curve; 5) Once the pressure drops to the safe threshold, lock the valve position to complete the emergency pressure relief.

8. The automatic pressure relief method for a six-sided top press according to claim 6, characterized in that: In step 4), the depressurization rate is adaptively matched according to the synthesis process stage.

9. The automatic pressure relief method for a six-sided top press according to claim 6, characterized in that: The emergency depressurization process simultaneously triggers audible and visual alarms and records depressurization data.

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