Optimized manufacturing system and method for plunger pump valve plate based on real-time additive and subtractive manufacturing

Abstract

This invention discloses a plunger pump distribution plate optimization manufacturing system and method based on real-time additive and subtractive manufacturing. The system includes an additive manufacturing center, a subtractive manufacturing center, a multi-degree-of-freedom robot, a pressure and flow characteristic testing center, a high-performance computing platform, a cloud platform, a data gateway, vibration sensors, noise sensors, pressure sensors, flow sensors, temperature sensors, a drive motor, and a plunger pump mounting platform. This invention enables real-time testing of the damping groove optimization process, improving the efficiency of product optimization design.

Description

Technical Field

[0001] This invention relates to the field of optimized design and manufacturing of plunger pumps, and in particular to an optimized manufacturing system and method for plunger pump distribution plate based on real-time additive and subtractive manufacturing. Background Technology

[0002] Structural optimization of plunger pumps has long been a focus of attention in both industry and academia. In recent years, with the development of simulation technology, some research results have been achieved in optimizing the structure of plunger pumps through simulation calculations. However, the optimization process based on simulation software often lacks experimental verification. Furthermore, the verification of optimization results usually cannot be linked with the simulation process in real time, and the feasibility and accuracy of the optimization results lack verification. Summary of the Invention

[0003] To address the disconnect between simulation calculations and experimental testing in the structural optimization of plunger pumps, this invention proposes a plunger pump distribution plate optimization manufacturing system and method based on real-time additive and subtractive manufacturing. This system enables real-time linkage and data interaction between simulation calculations and experimental testing in the optimization process. Furthermore, through a modular design approach and the application of additive and subtractive manufacturing technology, the remanufacturing process of the optimized plunger pump structure is simplified, thereby improving optimization manufacturing efficiency.

[0004] The objective of this invention is achieved through the following technical solution:

[0005] An optimized manufacturing system for plunger pump distribution plate based on real-time additive and subtractive manufacturing includes an additive manufacturing center, a subtractive manufacturing center, a multi-degree-of-freedom robot, a pressure and flow characteristic testing center, a high-performance computing platform, a cloud platform, a data gateway, vibration sensors, noise sensors, pressure sensors, flow sensors, temperature sensors, drive motors, and a plunger pump mounting frame.

[0006] The test pump, consisting of a modular rotor assembly and a modular end cap assembly coaxially connected, is mounted on the plunger pump mounting stand. The drive motor is also mounted on the plunger pump mounting stand for connection with the test pump.

[0007] The pressure and flow characteristic testing center is connected to the pump under test via an oil pipe. The pressure sensor, flow sensor, and temperature sensor are installed on the oil pipe to evaluate the operating status of the pump under test in real time. The vibration sensor is installed on the modular end cap assembly, and the noise sensor is installed around the pump under test.

[0008] The multi-degree-of-freedom robotic arm is used to transport modular end cap assemblies to the additive manufacturing center and the subtractive manufacturing center;

[0009] The additive manufacturing center and the subtractive manufacturing center respectively achieve real-time optimization and correction of the damping groove structure through additive or subtractive manufacturing;

[0010] The high-performance computing platform is connected to the pressure and flow characteristic testing center, pressure sensor, flow sensor, temperature sensor, drive motor, additive manufacturing center, subtractive manufacturing center, and multi-degree-of-freedom robotic arm. Through a digital twin system, it transmits the data detected by the entire optimized manufacturing system to the optimized design model of the damping groove, realizing online optimization design of the damping groove structure. The cloud platform is connected to the high-performance computing platform through the data gateway, and uploads test data, simulation results, and optimization data to the cloud database in real time.

[0011] Furthermore, the high-performance computing platform adopts a cloud-based computer or an offline-deployed computing platform.

[0012] Furthermore, a motor vibration isolation cavity is provided outside the drive motor.

[0013] A method for optimizing the manufacturing of a plunger pump distributor plate based on real-time additive and subtractive manufacturing, the method being implemented based on the aforementioned optimized manufacturing system for a plunger pump distributor plate based on real-time additive and subtractive manufacturing, and the method comprising the following steps:

[0014] Step 1: Parameterize the damping groove structure of the distribution plate, and reconstruct the model of the entire pump on a high-performance computing platform to obtain a virtual prototype;

[0015] Step 2: The performance of the entire pump is tested at the pressure and flow characteristic testing center, and data from the vibration sensor, noise sensor, pressure sensor, flow sensor, and temperature sensor are collected to evaluate the operating status of the entire pump in real time; the same calculation data is extracted from the virtual prototype to correct the boundary conditions; after calculating the optimal model under the current operating conditions through the optimization model of the virtual prototype, the optimized model is reconstructed in real time.

[0016] Step 3: The reconstruction requirements are transmitted to the additive manufacturing center and the subtractive manufacturing center. The modular end cap assembly is disassembled using the multi-degree-of-freedom robot and then sent to the additive manufacturing center and the subtractive manufacturing center for remanufacturing of the distribution plate damping groove. The optimal damping groove model at this time is directly processed and experimentally evaluated. If the test results meet the design requirements, the structural parameters are finalized. If the requirements are not met, the design is re-optimized until the optimal damping groove structural parameters are obtained.

[0017] The beneficial effects of this invention are as follows:

[0018] 1. By adopting this invention, it is possible to collect multi-source data such as pressure, flow rate, temperature, vibration, and noise of the system under the operation of the plunger pump in real time, which can be used as the basis and information for correcting the boundary conditions of the simulation model and improving the calculation accuracy of the simulation model.

[0019] 2. This invention, through real-time linkage between additive manufacturing center and subtractive manufacturing center, can effectively optimize the manufacturing of damping groove structure without replacing the distribution plate structural components, effectively saving optimization manufacturing costs and improving the efficiency of experimental verification.

[0020] 3. By building a cloud platform, it is possible to accumulate and analyze optimization data, which makes it easier for users to build an optimization database related to their own products and realize the datafication of products.

[0021] 4. By adopting this invention, and by inputting an intelligent structural optimization model into a high-performance computing center, the optimal structure that meets the optimization requirements can be automatically iterated by setting optimization goals. At the same time, the simulation results during the process can be verified and corrected in real time by combining the optimization manufacturing system, thereby improving the feasibility of the optimization results. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of a distribution plate optimization manufacturing system according to one embodiment of the present invention.

[0023] Figure 2 This is a flowchart of the optimized manufacturing method for the plunger pump distribution plate of the present invention.

[0024] In the figure, the components are: 1. Modular rotor assembly; 2. Modular end cap assembly; 3. Additive manufacturing center; 4. Subtractive manufacturing center; 5. Multi-degree-of-freedom robot; 6. Pressure and flow characteristic testing center; 7. High-performance computing platform; 8. Cloud platform; 9. Data gateway; 10. Vibration sensor; 11. Noise sensor; 12. Pressure sensor; 13. Flow sensor; 14. Temperature sensor; 15. Drive motor; 16. Plunger pump mounting frame; 17. Motor vibration isolation cavity. Detailed Implementation

[0025] The present invention will be described in detail below with reference to the accompanying drawings and preferred embodiments. The purpose and effects of the present invention will become clearer. It should be understood that the specific embodiments described herein are merely for explaining the present invention and are not intended to limit the present invention.

[0026] like Figure 1 As shown, the plunger pump distribution plate optimization manufacturing system based on real-time additive and subtractive manufacturing in this embodiment includes an additive manufacturing center 3, a subtractive manufacturing center 4, a multi-degree-of-freedom robot 5, a pressure and flow characteristic testing center 6, a high-performance computing platform 7, a cloud platform 8, a data gateway 9, a vibration sensor 10, a noise sensor 11, a pressure sensor 12, a flow sensor 13, a temperature sensor 14, a drive motor 15, and a plunger pump mounting stand 16.

[0027] The modular rotor assembly 1 and the modular end cap assembly 2, which are coaxially connected, form the pump under test. The pump under test and the drive motor 15 are mounted on the plunger pump mounting stand 16. The pressure-flow characteristic testing center 6 is connected to the pump under test via an oil pipe. Pressure sensor 12, flow sensor 13, and temperature sensor 14 are installed on the pipeline of the pressure-flow characteristic testing center 6. Vibration sensor 10 is installed on the modular end cap assembly 2. Noise sensors 11 are distributed in a spherical array around the pump under test. Multi-degree-of-freedom manipulator 5 is installed on the manufacturing system platform for moving the modular end cap assembly 2. High-performance computing platform 7 transmits system detection data to the damping groove optimization design model through a digital twin system to realize online optimization design of the damping groove structure. Cloud platform 8 is connected to high-performance computing platform 7 through data gateway 9 to upload test data and optimization data to the cloud database in real time. Additive manufacturing center 3 and subtractive manufacturing center 4 are respectively arranged on both sides of pressure-flow characteristic testing center 6. The modular end cap assembly 2 can be disassembled and moved to additive manufacturing center 3 and subtractive manufacturing center 4 by multi-degree-of-freedom manipulator for real-time optimization and correction of the damping groove structure.

[0028] To reduce the noise of the drive motor 15, a motor vibration isolation cavity 17 is provided outside the drive motor 15.

[0029] As one implementation method, the high-performance computing platform can be either a cloud-based computer or an offline-deployed computing platform.

[0030] like Figure 2 As shown, the plunger pump distribution plate optimization manufacturing method based on real-time additive and subtractive manufacturing in this embodiment is implemented based on a plunger pump distribution plate optimization manufacturing system based on real-time additive and subtractive manufacturing. For the optimization problem of the damping groove of the distribution plate in an axial plunger pump, an optimization method combining real-time physical prototypes and virtual prototypes is adopted. Simultaneously, an intelligent robotic arm is used in conjunction with additive manufacturing centers and subtractive manufacturing centers to perform real-time remanufacturing of the distribution plate. The method specifically includes the following steps:

[0031] Step 1: Parameterize the damping groove structure of the distribution plate, and reconstruct the model of the entire pump on the high-performance computing platform 7 to obtain a virtual prototype;

[0032] Step 2: The performance of the entire pump is tested at the pressure and flow characteristic testing center 6, and data from the vibration sensor 10, noise sensor 11, pressure sensor 12, flow sensor 13, and temperature sensor 14 are collected to evaluate the operating status of the entire pump in real time; the same calculation data is extracted from the virtual prototype to correct the boundary conditions; after calculating the optimal model under the current operating conditions through the optimization model of the virtual prototype, the optimized model is reconstructed in real time;

[0033] Step 3: The reconstruction requirements are transmitted to the additive manufacturing center 3 and the subtractive manufacturing center 4. The modular end cap assembly is disassembled using the multi-degree-of-freedom robot arm 5 and then sent to the additive manufacturing center 3 and the subtractive manufacturing center 4 for remanufacturing of the distribution plate damping groove. The optimal damping groove model at this time is directly processed and experimentally evaluated. If the test results meet the design requirements, the structural parameters are finalized. If the requirements are not met, the design is re-optimized until the optimal damping groove structural parameters are obtained.

[0034] It will be understood by those skilled in the art that the above descriptions are merely preferred examples of the invention and are not intended to limit the invention. Although the invention has been described in detail with reference to the foregoing examples, those skilled in the art can still modify the technical solutions described in the foregoing examples or make equivalent substitutions for some of the technical features. All modifications and equivalent substitutions made within the spirit and principles of the invention should be included within the scope of protection of the invention.

Claims

1. A plunger pump distribution plate optimization manufacturing system based on real-time additive and subtractive manufacturing, characterized in that, Including additive manufacturing center (3), subtractive manufacturing center (4), multi-degree-of-freedom robot (5), pressure and flow characteristic testing center (6), high-performance computing platform (7), cloud platform (8), data gateway (9), vibration sensor (10), noise sensor (11), pressure sensor (12), flow sensor (13), temperature sensor (14), drive motor (15), plunger pump mounting stand (16); The test pump, consisting of a modular rotor assembly (1) and a modular end cap assembly (2) connected coaxially, is mounted on the plunger pump mounting stand (16). The drive motor (15) is also mounted on the plunger pump mounting stand (16) for connection with the test pump. The pressure and flow characteristic test center (6) is connected to the pump under test through an oil pipe. The pressure sensor (12), flow sensor (13), and temperature sensor (14) are installed on the oil pipe to evaluate the operating status of the pump under test in real time. The vibration sensor (10) is installed on the modular end cap assembly (2), and the noise sensor (11) is installed around the pump under test. The multi-degree-of-freedom manipulator (5) is used to transport the modular end cap assembly (2) to the additive manufacturing center (3) and the subtractive manufacturing center (4); The additive manufacturing center (3) and the subtractive manufacturing center (4) respectively achieve real-time optimization and correction of the damping groove structure through additive or subtractive manufacturing; The high-performance computing platform (7) is electrically connected to the pressure and flow characteristic testing center (6), pressure sensor (12), flow sensor (13), temperature sensor (14), drive motor (15), additive manufacturing center (3), subtractive manufacturing center (4), and multi-degree-of-freedom manipulator (5). Through the digital twin system, the data detected by the entire optimized manufacturing system is transmitted to the optimized design model of the damping groove to realize the online optimization design of the damping groove structure. The cloud platform (8) is connected to the high-performance computing platform (7) through the data gateway (9) and uploads the test data, simulation results and optimization data to the cloud database in real time.

2. The optimized manufacturing system for plunger pump distribution plate based on real-time additive and subtractive manufacturing according to claim 1, characterized in that, The high-performance computing platform can be a cloud-based computer or an offline-deployed computing platform.

3. The optimized manufacturing system for plunger pump distribution plate based on real-time additive and subtractive manufacturing according to claim 1, characterized in that, The drive motor (15) is provided with a motor vibration isolation cavity (17) outside.

4. A method for optimizing the manufacturing of a plunger pump distribution plate based on real-time additive and subtractive manufacturing, characterized in that, This method is based on the plunger pump distribution plate optimization manufacturing system based on real-time additive and subtractive manufacturing according to any one of claims 1 to 3, and the method includes the following steps: Step 1: Parameterize the damping groove structure of the distribution plate, and reconstruct the model of the whole pump on the high-performance computing platform (7) to obtain a virtual prototype; Step 2: The performance of the entire pump is tested at the pressure and flow characteristic test center (6), and data from the vibration sensor (10), noise sensor (11), pressure sensor (12), flow sensor (13), and temperature sensor (14) are collected to evaluate the operating status of the entire pump in real time; the same calculation data is extracted from the virtual prototype to correct the boundary conditions; after calculating the optimal model under the current operating conditions through the optimization model of the virtual prototype, the optimized model is reconstructed in real time. Step 3: The reconstruction requirements are transmitted to the additive manufacturing center (3) and the subtractive manufacturing center (4). The modular end cap assembly is disassembled using the multi-degree-of-freedom robot (5) and then sent to the additive manufacturing center (3) and the subtractive manufacturing center (4) for remanufacturing of the distribution plate damping groove. The optimal damping groove model is directly processed and experimentally evaluated. If the test results meet the design requirements, the structural parameters are finalized. If the requirements are not met, the design is re-optimized until the optimal damping groove structural parameters are obtained.

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