Automatic control system and control method for energy consumption optimization of hydraulic forging press

Abstract

The invention discloses an automatic control system and method for energy consumption optimization of a hydraulic forging press. The method comprises the steps that the model of a forged object is obtained; determining a forging scheme according to the model of the forged object; a pressure set value needed by current forging is determined through the forging scheme; working parameters of the variable frequency motor are determined according to the pressure set value, and forging energy consumption is calculated; the forging energy consumption is verified, and when the forging energy consumption is the minimum forging energy consumption, the hydraulic machine is controlled to conduct forging work according to the working parameters of the variable frequency motor; after each time of forging is finished, the state of the forged object after forging is obtained; and determining a pressure set value required by next forging according to the state of the forged object after forging. The energy consumption of the hydraulic press is reduced by acquiring the forging state of the forged object, monitoring and analyzing the running state of the hydraulic forging press in real time and controlling the output flow of the hydraulic pump by adjusting the rotating speed of the motor.

Description

Technical Field

[0001] The present application relates to the technical field of forging hydraulic press control, and more specifically, to an automatic control system and control method for optimizing energy consumption of a forging hydraulic press. Background Art

[0002] Forging hydraulic presses are important equipment in industrial manufacturing and are widely used in the forming and processing of metal materials. However, in actual use, traditional energy consumption management methods are often based on experience or fixed control strategies, adjusted manually, lack data-driven intelligent decision support, and are difficult to adapt to complex and changing working conditions. At the same time, during long-term operation, hydraulic presses are prone to increased energy consumption and reduced production efficiency due to wear, leakage and other reasons.

[0003] Therefore, the prior art has defects and is in urgent need of improvement. Summary of the invention

[0004] In view of the above problems, the purpose of the present invention is to provide an automatic control system and control method for optimizing the energy consumption of a forging hydraulic press, which obtains the forging state of the forging object, monitors and analyzes the operating state of the forging hydraulic press in real time, controls the output flow of the hydraulic pump by adjusting the motor speed, and reduces the energy consumption of the hydraulic press.

[0005] A first aspect of the present invention provides an automatic control method for optimizing energy consumption of a forging hydraulic press, comprising:

[0006] Get the forging object model;

[0007] Determining a forging plan according to the forging object model;

[0008] Determine the pressure setting value required for the current forging through the forging plan;

[0009] Determine the working parameters of the variable frequency motor according to the pressure setting value, and calculate the forging energy consumption; the working parameters of the variable frequency motor include the motor speed level corresponding to the pressure setting value, the third speed level in the return stage, the second speed level in the falling stage, the first speed level and the first acceleration in the boost stage;

[0010] The forging energy consumption is verified, and when the forging energy consumption is the minimum forging energy consumption, the hydraulic press is controlled to perform forging work according to the working parameters of the variable frequency motor;

[0011] After each forging is completed, the state of the forged object is obtained;

[0012] The pressure setting value required for the next forging is determined according to the state of the forged object after the forging.

[0013] In this solution, the step of obtaining the forging object model and determining the forging solution according to the forging object model includes:

[0014] Acquire detection image data;

[0015] Determine the model of the forged object through the detection image data;

[0016] Screening the historical forging data in the database according to the forging object model to determine the historical forging data with the minimum average power consumption in each forging stage;

[0017] The historical forging plans corresponding to the historical forging data with the minimum average power consumption in each forging stage are integrated to determine the forging plan.

[0018] In this solution, the step of determining the operating parameters of the variable frequency motor according to the pressure setting value includes:

[0019] According to the pressure setting value p of the next forging x(i+1) , pressure setting value p x(i+1) Motor power P corresponding to motor speed level j j , motor power P at motor speed level h h , acceleration a j-h and acceleration time t a(j-h) Determine the first forging pressure adjustment interval [p a(i+1)min ,p a(i+1)max ];

[0020] According to the first forging pressure adjustment interval [p a(i+1)min ,p a(i+1)max ] Determine multiple first forging pressures p a(i+1)n ;p a(i+1)min ≤p b(i+1) ≤p a(i+1)max ;

[0021] Calculate each first forging pressure p in turn a(i+1)n Adjust to the pressure setting value p x(i+1) The pressurizing energy consumption is calculated, and a first relationship curve between the first forging pressure and the pressurizing energy consumption is drawn;

[0022] Determine the minimum pressurization energy consumption W according to the first relationship curve 1(i+1) and the minimum pressurization energy consumption W 1(i+1) The corresponding second forging pressure p b(i+1) ;

[0023] The second forging pressure p b(i+1) The corresponding motor speed level is determined as the first speed level, and the second forging pressure p b(i+1) The corresponding acceleration is determined as the first acceleration, and the second forging pressure p b(i+1) The corresponding acceleration time is determined as the first acceleration time;

[0024] The maximum first forging pressure p in the first forging pressure adjustment range a(i+1)max and the minimum first forging pressure p a(i+1)min Determine the corresponding falling start height interval [H a(i+1)min ,H a(i+1)max ];

[0025] According to the falling start height interval [H a(i+1)min ,H a(i+1)max ]Determine multiple drop start heights H a(i+1)m ;

[0026] According to the second forging pressure p b(i+1) and the preset maximum falling time threshold to calculate each falling starting height H a(i+1)m The minimum falling energy consumption W 2(i+1) The corresponding falling starting height is determined as the first falling starting height, and the minimum falling energy consumption W is 2(i+1) The corresponding motor speed level is determined as the second speed level.

[0027] This plan also includes:

[0028] Determine the first falling starting height as the first return height;

[0029] Determine the return displacement L according to the first return height;

[0030] According to the return displacement L, a relationship curve between the return power and the return time corresponding to each return motor speed level is drawn, and the return energy consumption W corresponding to each return motor speed level is calculated. 3(i) ;

[0031] The return motor speed level corresponding to the minimum return energy consumption is determined as the third speed level.

[0032] In this solution, the calculation of forging energy consumption includes:

[0033] Calculate the forging energy consumption W required for forging work i+1 (i+1) ;

[0034] W (i+1) =k1×W 1(i+1) +k2×W 2(i+1) +k3×W 3(i) ;

[0035] Among them, k1, k2 and k3 are all influencing factors, and the values ​​of influencing factors k1, k2 and k3 are determined according to the difference between the actual energy consumption and the predicted energy consumption in the current forging work i.

[0036] In this solution, the verification of the forging energy consumption includes:

[0037] From the first forging pressure adjustment interval [p a(i+1)min ,p a(i+1)max ] randomly select one or more first forging pressures p a(i+1)q , calculate the one or more first forging pressures p a(i+1)q The corresponding one or more verification forging energy consumption W (i+1)q ;

[0038] The one or more verification forging energy consumption W (i+1)q Respectively with forging energy consumption W (i+1) Make a comparison;

[0039] When forging energy consumption W (i+1) When it is the minimum value, determine the forging energy consumption W (i+1) Minimum forging energy consumption;

[0040] Otherwise, calculate each first forging pressure p a(i+1)n The corresponding forging energy consumption W (i+1)n , multiple forging energy consumption W (i+1)n The minimum value of is determined as the final forging energy consumption W (i+1) .

[0041] This plan also includes:

[0042] After each hydraulic work is completed, the influencing factors k1, k2 and k3 are corrected based on the difference between the actual energy consumption and the predicted energy consumption; the actual energy consumption includes the actual pressurization energy consumption in the pressurization stage, the actual falling energy consumption in the falling stage and the actual return energy consumption in the return stage; the predicted energy consumption includes the minimum pressurization energy consumption in the pressurization stage, the minimum falling energy consumption in the falling stage and the minimum return energy consumption in the return stage.

[0043] In this solution, the step of determining the pressure setting value required for the next forging according to the state of the forged object after forging includes:

[0044] Compare the state of the forged object after forging with the state of the forged object before forging to determine the actual forging progress;

[0045] Compare the actual forging progress with the expected forging progress to determine whether the error condition is met;

[0046] If yes, the pressure setting value for the next forging is retrieved through the forging plan;

[0047] If not, the pressure setting value for the next forging is determined according to the state of the forged object after forging.

[0048] This plan also includes:

[0049] During the forging process, the first warning score is calculated based on the real-time pressure, stamping time and hydraulic oil temperature;

[0050] When the first warning score is greater than or equal to the preset warning score threshold, the current forging is ended and the hydraulic press is controlled to return.

[0051] The second aspect of the present invention provides an automatic control system for optimizing energy consumption of a forging hydraulic press, comprising:

[0052] A data acquisition module, used to obtain the model of the forging object;

[0053] A forging scheme generating module, used for determining a forging scheme according to the forging object model;

[0054] A first pressure value adjustment module, used to determine the pressure setting value required for the current forging according to the forging scheme;

[0055] A motor working parameter setting module, used to determine the working parameters of the variable frequency motor according to the pressure setting value and calculate the forging energy consumption; the working parameters of the variable frequency motor include the motor speed level corresponding to the pressure setting value, the third speed level in the return stage, the second speed level in the falling stage, the first speed level and the first acceleration in the boost stage;

[0056] An energy consumption verification module, used to verify the forging energy consumption, and when the forging energy consumption is the minimum forging energy consumption, control the hydraulic press to perform forging work according to the working parameters of the variable frequency motor;

[0057] The second pressure value adjustment module is used to obtain the state of the forged object after each forging is completed; and determine the pressure setting value required for the next forging according to the state of the forged object after forging.

[0058] The third aspect of the present invention provides a computer-readable storage medium, which includes a program for an automatic control method for optimizing energy consumption of a forging hydraulic press. When the program for an automatic control method for optimizing energy consumption of a forging hydraulic press is executed by a processor, the steps of the automatic control method for optimizing energy consumption of a forging hydraulic press as described above are implemented.

[0059] The present invention discloses an automatic control system and control method for optimizing energy consumption of a forging hydraulic press, the method comprising: obtaining a forging object model; determining a forging scheme according to the forging object model; determining a pressure setting value required for current forging through the forging scheme; determining a variable frequency motor working parameter according to the pressure setting value, and calculating the forging energy consumption; verifying the forging energy consumption, and when the forging energy consumption is the minimum forging energy consumption, controlling the hydraulic press to perform forging according to the variable frequency motor working parameter; obtaining the state of the forged object after forging after each forging; and determining the pressure setting value required for the next forging according to the state of the forged object after forging. The present invention reduces the energy consumption of the hydraulic press by obtaining the forging state of the forging object, monitoring and analyzing the operating state of the forging hydraulic press in real time, and controlling the output flow of the hydraulic pump by adjusting the motor speed. BRIEF DESCRIPTION OF THE DRAWINGS

[0060] Figure 1 A flow chart showing an automatic control method for optimizing energy consumption of a forging hydraulic press provided by the present invention is shown;

[0061] Figure 2 A flow chart of the forging scheme generation method provided by the present invention is shown;

[0062] Figure 3 A flow chart of the forging energy consumption verification method provided by the present invention is shown;

[0063] Figure 4 A block diagram of an energy consumption optimization automatic control system for a forging hydraulic press provided by the present invention is shown. DETAILED DESCRIPTION

[0064] In order to more clearly understand the above-mentioned purpose, features and advantages of the present invention, the present invention is further described in detail below in conjunction with the accompanying drawings and specific embodiments. It should be noted that the embodiments of the present application and the features in the embodiments can be combined with each other without conflict.

[0065] In the following description, many specific details are set forth to facilitate a full understanding of the present invention. However, the present invention may also be implemented in other ways different from those described herein. Therefore, the protection scope of the present invention is not limited to the specific embodiments disclosed below.

[0066] Figure 1 A flow chart of an energy consumption optimization automatic control method for a forging hydraulic press provided by the present invention is shown.

[0067] like Figure 1 As shown, the present invention discloses an automatic control method for optimizing energy consumption of a forging hydraulic press, comprising:

[0068] S102, obtaining a forging object model;

[0069] S104, determining a forging plan according to the model of the forging object;

[0070] S106, determining the pressure setting value required for the current forging through the forging plan;

[0071] S108, determining the working parameters of the variable frequency motor according to the pressure setting value, and calculating the forging energy consumption; the working parameters of the variable frequency motor include the motor speed level corresponding to the pressure setting value, the third speed level in the return stage, the second speed level in the falling stage, the first speed level and the first acceleration in the boost stage;

[0072] S110, verifying the forging energy consumption, and when the forging energy consumption is the minimum forging energy consumption, controlling the hydraulic press to perform forging according to the working parameters of the variable frequency motor;

[0073] S112, after each forging is completed, obtaining the state of the forged object after forging;

[0074] S114, determining the pressure setting value required for the next forging according to the state of the forged object after forging.

[0075] According to an embodiment of the present invention, detection image data of a forging object is acquired by a camera device or other equipment, and the forging object model of the forging object is determined by analyzing the detection image data. Historical forging data of the same forging object model is screened from a database, and the historical forging data with the minimum average power consumption in each forging stage is calculated. The corresponding forging parameters and historical forging schemes are extracted and integrated to determine the forging scheme for the current forging object.

[0076] A forging process consists of a return phase, a drop phase and a forging phase. The forging phase includes a pressurization phase and a stamping phase. When the hydraulic press is started for the first time for forging, the hydraulic press drops from the top, that is, it does not include a return phase. The pressure setting value of the next forging process of the hydraulic press falling is determined through the forging plan to make the forged object meet the expected forging conditions. The first forging pressure adjustment interval when the hydraulic press contacts the forging object is determined according to the pressure setting value and the maximum motor acceleration time of the pressurization phase preset by the system. Multiple first forging pressures are selected from the first forging pressure adjustment interval, and the pressurization energy consumption from each first forging pressure to the pressure setting value is calculated respectively. The first relationship curve between the first forging pressure and the pressurization energy consumption is drawn. The minimum pressurization energy consumption and the corresponding second forging pressure are determined through the first relationship curve. The working parameters of the variable frequency motor in the pressurization phase, including the first speed level, the first acceleration and the first acceleration time, are determined through the second forging pressure. Then, the first forging pressure adjustment interval [p a(i+1)min ,p a(i+1)max ] and historical hydraulic data to determine the hydraulic press to eliminate pressure fluctuations before contacting the forging object and meet the drop start height range [H a(i+1)min ,Ha(i+1)max ] Calculate the first drop height and the second speed level in the drop height interval that satisfy the minimum drop energy consumption under the second forging pressure before the hydraulic press contacts the forging object, and determine the working parameters of the variable frequency motor in the drop stage. And determine the third speed level corresponding to the minimum return energy consumption in the return stage through the first drop height, and determine the working parameters of the variable frequency motor in the return stage.

[0077] In addition, in order to ensure the forging energy consumption W (i+1) For the minimum forging energy consumption, in the first forging pressure adjustment range [p a(i+1)min ,p a(i+1)max ] randomly select one or more first forging pressures p a(i+1)q , calculate the corresponding verification forging energy consumption W (i+1)q , when the forging energy consumption W (i+1) All are less than the energy consumption W of each verification forging (i+1)q When determining the forging energy consumption W (i+1) In the next forging process, the motor speed of the variable frequency motor is adjusted according to the working parameters of the variable frequency motor in the return stage, the working parameters of the variable frequency motor in the falling stage and the working parameters of the variable frequency motor in the pressurizing stage, so as to ensure that the energy consumption of each forging process is the minimum energy consumption.

[0078] After each forging process is completed, the pressure setting value for the next forging is determined according to the state of the forging object after forging. When the actual forging progress of the forging object does not meet the expected forging progress, the pressure setting value for the next forging is determined according to the state of the forging object after forging; when the actual forging progress of the forging object meets the expected forging progress, the pressure setting value for the next forging is called through the forging plan.

[0079] Figure 2 A flow chart of the forging plan generating method provided by the present invention is shown.

[0080] like Figure 2 As shown, according to an embodiment of the present invention, obtaining a forging object model and determining a forging scheme according to the forging object model include:

[0081] S202, acquiring detection image data;

[0082] S204, determining the model of the forging object by detecting the image data;

[0083] S206, screening the historical forging data in the database according to the forging object model, and determining the historical forging data with the minimum average power consumption in each forging stage;

[0084] S208, integrating historical forging plans corresponding to historical forging data with the minimum average power consumption in each forging stage to determine a forging plan.

[0085] It should be noted that during the hydraulic press forging process, the system will collect various forging parameters (including forging object model, motor speed level, acceleration, acceleration time, and forging energy consumption during the hydraulic press return, drop and pressurization stages, etc.), generate historical forging data and store them in the database. After determining the forging object model of the forged object, the historical forging data in the database are screened according to the forging object model, and the average power consumption of the historical forging data of each same forging object model at each forging stage is calculated in turn, and the historical forging data with the minimum average power consumption at each forging stage is determined, and the corresponding forging parameters and historical forging schemes are extracted for integration to determine the forging scheme for the current forging object.

[0086] The forging stage of the forged object is determined by the system according to the state change of the forged object, etc. For example, when the forged object needs to be forged on multiple sides, the forging stages are divided according to the forging requirements of each forging side.

[0087] According to an embodiment of the present invention, determining the operating parameters of the variable frequency motor according to the pressure setting value includes:

[0088] According to the pressure setting value p of the next forging x(i+1) , pressure setting value p x(i+1) Motor power P corresponding to motor speed level j j , motor power P at motor speed level h h , acceleration a j-h and acceleration time t a(j-h) Determine the first forging pressure adjustment interval [p a(i+1)min ,p a(i+1)max ];

[0089] According to the first forging pressure adjustment interval [p a(i+1)min ,p a(i+1)max ] Determine multiple first forging pressures p a(i+1)n ;p a(i+1)min ≤p b(i+1) ≤p a(i+1)max ;

[0090] Calculate each first forging pressure p in turn a(i+1)n Adjust to the pressure setting value p x(i+1) The pressurizing energy consumption is calculated, and a first relationship curve between the first forging pressure and the pressurizing energy consumption is drawn;

[0091] Determine the minimum pressurization energy consumption W according to the first relationship curve 1(i+1) and minimum pressurization energy consumption W 1(i+1) The corresponding second forging pressure p b(i+1) ;

[0092] The second forging pressure p b(i+1) The corresponding motor speed level is determined as the first speed level, and the second forging pressure p b(i+1) The corresponding acceleration is determined as the first acceleration, and the second forging pressure p b(i+1) The corresponding acceleration time is determined as the first acceleration time;

[0093] The maximum first forging pressure p in the first forging pressure adjustment range a(i+1)max and the minimum first forging pressure p a(i+1)min Determine the corresponding falling start height interval [H a(i+1)min ,H a(i+1)max ];

[0094] According to the falling start height interval [H a(i+1)min ,H a(i+1)max ]Determine multiple drop start heights H a(i+1)m ;

[0095] According to the second forging pressure p b(i+1) and the preset maximum falling time threshold to calculate each falling starting height H a(i+1)m The minimum falling energy consumption W 2(i+1) The corresponding falling starting height is determined as the first falling starting height, and the minimum falling energy consumption W is 2(i+1) The corresponding motor speed level is determined as the second speed level.

[0096] It should be noted that when the hydraulic press contacts the forging object, the load on the hydraulic press increases, and it is necessary to increase the speed level of the variable frequency motor and the hydraulic pressure to meet the forging pressure of the forging object. The system defaults to entering the pressurization stage when the hydraulic press contacts the forging object. Those skilled in the art can set the starting height of the pressurization stage according to actual needs.

[0097] First, obtain the pressure setting value p for the next forging x(i+1) and the motor power P corresponding to the motor speed level j j , combined with the motor parameters of the variable frequency motor, through the system preset pressure change calculation method (such as historical data comparison, model calculation, etc.) to determine that the hydraulic press pressure can be adjusted to the pressure setting value p before the system preset maximum motor acceleration time x(i+1) The maximum first forging pressure p a(i+1)max and the minimum first forging pressure p a(i+1)min , determine the first forging pressure adjustment interval [p a(i+1)min ,p a(i+1)max ], and adjust the pressure from the first forging pressure interval [p a(i+1)min ,p a(i+1)max ] select multiple first forging pressures p a(i+1)n. Determine the first forging pressure p a(i+1)n Corresponding motor speed level h, motor power P h , acceleration a h-j and acceleration time t a(h-j) , divided into several small time periods according to the acceleration time, the energy consumption of each time period is determined by the product of the average value of the motor power at the beginning and end of each time period and the time length of the time period, and the energy consumption of all time periods is added to determine the pressurization energy consumption of the hydraulic press from the first forging pressure to the pressure setting value. Establish a coordinate axis with the first forging pressure as the horizontal axis and the pressurization energy consumption as the vertical axis, input each first forging pressure and the corresponding pressurization energy consumption into the coordinate axis, connect the coordinate points generated by adjacent first forging pressures, and perform smoothing to determine the first relationship curve between the first forging pressure and the pressurization energy consumption. The minimum value of the pressurization energy consumption in the first relationship curve is determined as the minimum pressurization energy consumption W 1(i+1) , the corresponding first forging pressure is the second forging pressure p b(i+1) .

[0098] At the beginning of the falling stage of the hydraulic press, since the motor has just started working, there will be a certain pressure fluctuation due to the internal load of the hydraulic press (such as the resistance caused by the flow of liquid between the internal components of the hydraulic press). If the hydraulic press needs to return to the highest position frequently for the next operation, this may increase working time, reduce working efficiency and increase energy consumption. The maximum first forging pressure p of the first forging pressure adjustment range a(i+1)max and the minimum first forging pressure p a(i+1)min , combined with historical hydraulic data analysis, to determine the hydraulic press to eliminate pressure fluctuations before contacting the forging object, to meet the requirements of stable pressure drop and the maximum drop start height H a(i+1)max Minimum drop starting height H a(i+1)min , determine the falling start height interval [H a(i+1)min ,H a(i+1)max ]. The greater the first forging pressure, the higher the required falling start height. According to the system preset height interval from the falling start height interval [H a(i+1)min ,H a(i+1)max ]Select multiple drop start heights H a(i+1)m , determine the starting height H of each drop a(i+1)m Before the hydraulic press contacts the forging object, the hydraulic press pressure is adjusted to the second forging pressure p b(i+1) The motor speed level and the falling time are calculated and the product of the two is used to determine the starting height H of each fall. a(i+1)m The falling energy consumption.

[0099] According to an embodiment of the present invention, it also includes:

[0100] Determine the first falling starting height as the first return height;

[0101] Determine the return displacement L according to the first return height;

[0102] According to the return displacement L, the relationship curve between the return power and the return time corresponding to each return motor speed level is drawn, and the return energy consumption W corresponding to each return motor speed level is calculated. 3(i) ;

[0103] The return motor speed level corresponding to the minimum return energy consumption is determined as the third speed level.

[0104] It should be noted that the return displacement L is determined by the first return height and the specification of the return hydraulic cavity, the return time corresponding to each return motor speed level is determined by calculating the return displacement L and the displacement speed corresponding to the return motor speed level, the corresponding relationship between the return power and the return time corresponding to each return motor speed level is determined, the return power and the return time at the same return motor speed level are multiplied to determine the return energy consumption corresponding to the return motor speed level, and the return motor speed level corresponding to the minimum return energy consumption is determined as the return motor speed level in the return stage.

[0105] According to an embodiment of the present invention, calculating forging energy consumption includes:

[0106] Calculate the forging energy consumption W required for forging work i+1 (i+1) ;

[0107] W (i+1) =k1×W 1(i+1) +k2×W 2(i+1) +k3×W 3(i) ;

[0108] Among them, k1, k2 and k3 are all influencing factors, and the values ​​of influencing factors k1, k2 and k3 are determined according to the difference between the actual energy consumption and the predicted energy consumption in the current forging work i.

[0109] It should be noted that the actual energy consumption in the pressurization stage, the drop stage and the return stage are all affected by different factors. For example, the pressurization stage is affected by the resistance load given by the forging object, the friction load between the components of the hydraulic press, the air resistance and liquid resistance encountered by the hydraulic press during operation, etc.; the drop stage and the return stage are mainly affected by the inertial load generated when the operation starts, the friction load between the components of the hydraulic press, the air resistance and liquid resistance encountered by the hydraulic press during operation, the temperature of the hydraulic oil, the leakage amount and other parameters, etc.; by setting the influencing factors k1, k2 and k3, the minimum pressurization energy consumption in the pressurization stage, the minimum drop energy consumption in the drop stage and the minimum return energy consumption in the return stage are corrected respectively, and the forging energy consumption required for forging work i+1 is determined.

[0110] Figure 3 A flow chart of the forging energy consumption verification method provided by the present invention is shown;

[0111] like Figure 3 As shown, according to an embodiment of the present invention, the forging energy consumption is verified, including:

[0112] S302, from the first forging pressure adjustment interval [p a(i+1)min ,p a(i+1)max ] randomly select one or more first forging pressures p a(i+1)q , calculate one or more first forging pressures p a(i+1)q The corresponding one or more verification forging energy consumption W (i+1)q ;

[0113] S304, one or more verification forging energy consumption W (i+1)q Respectively with forging energy consumption W (i+1) Make a comparison;

[0114] S306, when forging energy consumption W (i+1) When it is the minimum value, determine the forging energy consumption W (i+1) Minimum forging energy consumption;

[0115] S308, otherwise, calculate each first forging pressure p a(i+1)n The corresponding forging energy consumption W (i+1)n , multiple forging energy consumption W (i+1)n The minimum value of is determined as the final forging energy consumption W (i+1) .

[0116] It should be noted that when calculating the second forging pressure p b(i+1) Corresponding forging energy consumption W (i+1) At the same time, from the first forging pressure adjustment interval [p a(i+1)min ,p a(i+1)max ] randomly select one or more first forging pressures p a(i+1)q , calculate the corresponding one or more verification forging energy consumption W (i+1)q , used to calculate the forging energy consumption W (i+1) Verify the forging energy consumption W (i+1)q and forging energy consumption W (i+1) The calculation method is the same, and the values ​​of the influencing factors k1, k2 and k3 are also the same. (i+1)q Less than forging energy consumption W (i+1) , determine the second forging pressure p b(i+1) It is not the optimal forging pressure when the hydraulic press contacts the forging object. By fully calculating all the first forging pressures, multiple forging energy consumption W (i+1)n The minimum value of is determined as the final forging energy consumption W (i+1), according to the final forging energy consumption W (i+1) The motor control parameters (including speed level, acceleration and acceleration time, etc.) in the pressurization stage, the drop stage and the return stage are adjusted.

[0117] According to an embodiment of the present invention, it also includes:

[0118] After each hydraulic work is completed, the influencing factors k1, k2 and k3 are corrected based on the difference between the actual energy consumption and the predicted energy consumption; the actual energy consumption includes the actual pressurization energy consumption in the pressurization stage, the actual lowering energy consumption in the lowering stage and the actual return energy consumption in the return stage; the predicted energy consumption includes the minimum pressurization energy consumption in the pressurization stage, the minimum lowering energy consumption in the lowering stage and the minimum return energy consumption in the return stage.

[0119] It should be noted that the various parameters in the hydraulic press will change according to the use time of the hydraulic press. For example, the longer the working time, the higher the temperature of the hydraulic oil, the lower the viscosity, the better the fluidity, which may lead to a decrease in system pressure, etc. The actual energy consumption of the current hydraulic work in the pressurization stage, the drop stage and the return stage is obtained through the energy consumption monitoring module, and compared with the corresponding predicted energy consumption. The influencing factors k1, k2 and k3 are corrected according to the difference between the two. The hydraulic energy consumption of the next hydraulic work is calculated through the corrected influencing factors k1, k2 and k3 to determine the corresponding motor control parameters.

[0120] According to an embodiment of the present invention, determining the pressure setting value required for the next forging according to the state of the forged object after forging includes:

[0121] Compare the state of the forged object after forging with the state of the forged object before forging to determine the actual forging progress;

[0122] Compare the actual forging progress with the expected forging progress to determine whether the error condition is met;

[0123] If yes, the pressure setting value for the next forging is retrieved through the forging plan;

[0124] If not, the pressure setting value for the next forging is determined according to the state of the forged object after forging.

[0125] It should be noted that, affected by various factors, the forging object may not achieve the expected forging effect during the forging process of the forging object controlled by the hydraulic press according to the set motor control parameters. By obtaining the state of the forged object after forging (determined by parameters such as the detection image and the final height after the hydraulic press stamping is completed), the actual forging progress is calculated, and the progress difference between the actual forging progress and the expected forging progress is determined. When the progress difference is less than the preset progress difference threshold, the error condition is met; otherwise, the error condition is not met. Among them, the expected forging progress is set according to the forging stage of the forging object, and the preset progress difference threshold is set by the system according to actual needs. When the error condition is met, the pressure setting value of the next forging is called according to the forging sequence in the forging plan; when the error condition is not met, the pressure setting value of the next forging is determined according to the state of the forged object after forging and the state of the forged object corresponding to the expected forging progress, so that the forging effect of the forged object after forging meets the expected forging effect.

[0126] According to an embodiment of the present invention, it also includes:

[0127] During the forging process, the first warning score is calculated based on the real-time pressure, stamping time and hydraulic oil temperature;

[0128] When the first warning score is greater than or equal to the preset warning score threshold, the current forging is ended and the hydraulic press is controlled to return.

[0129] It should be noted that during the forging process, the real-time pressure, stamping time and hydraulic oil temperature are obtained through the pressure sensor, timer and temperature sensor, and the real-time pressure, stamping time and hydraulic oil temperature are multiplied by the corresponding influence weights respectively, and the calculation results are accumulated to determine the first warning score. Among them, the influence weights of the real-time pressure, stamping time and hydraulic oil temperature are set by the system, and the sum of the influence weights of the real-time pressure, stamping time and hydraulic oil temperature is 1.

[0130] When the first warning score is greater than or equal to the preset warning score threshold, the current forging work is at risk, the current forging work is forced to end, the motor control parameters of the next forging work are determined according to the forging object state of the forged object, and the hydraulic press is controlled to return. The preset warning score threshold is set by those skilled in the art according to actual needs.

[0131] Figure 4 A block diagram of an energy consumption optimization automatic control system for a forging hydraulic press provided by the present invention is shown.

[0132] like Figure 4 As shown, the second aspect of the present invention provides an automatic control system for optimizing energy consumption of a forging hydraulic press, comprising:

[0133] A data acquisition module, used to obtain the model of the forging object;

[0134] A forging plan generation module is used to determine the forging plan according to the forging object model;

[0135] A first pressure value adjustment module, used to determine the pressure setting value required for current forging through a forging plan;

[0136] The motor working parameter setting module is used to determine the working parameters of the variable frequency motor according to the pressure setting value and calculate the forging energy consumption; the working parameters of the variable frequency motor include the motor speed level corresponding to the pressure setting value, the third speed level in the return stage, the second speed level in the falling stage, the first speed level and the first acceleration in the boost stage;

[0137] Energy consumption verification module, used to verify forging energy consumption. When the forging energy consumption is the minimum forging energy consumption, the hydraulic press is controlled to perform forging work according to the working parameters of the variable frequency motor;

[0138] The second pressure value adjustment module is used to obtain the state of the forged object after each forging is completed; and determine the pressure setting value required for the next forging according to the state of the forged object after forging.

[0139] The third aspect of the present invention provides a computer-readable storage medium, which includes a program for an automatic control method for optimizing energy consumption of a forging hydraulic press. When the program for an automatic control method for optimizing energy consumption of a forging hydraulic press is executed by a processor, the steps of the above-mentioned automatic control method for optimizing energy consumption of a forging hydraulic press are implemented.

[0140] The information (including but not limited to user device information, user personal information, etc.), data (including but not limited to data used for analysis, stored data, displayed data, etc.) and signals (including but not limited to signals transmitted between user terminals and other devices, etc.) involved in this application are all authorized by the user or fully authorized by all parties, and the collection, use and processing of relevant data must comply with relevant laws, regulations and standards of relevant countries and regions. For example, the "forging object model" and "historical forging data" involved in this disclosure are all obtained with full authorization.

[0141] The present invention discloses an automatic control system and control method for optimizing energy consumption of a forging hydraulic press, the method comprising: obtaining a forging object model; determining a forging scheme according to the forging object model; determining a pressure setting value required for current forging through the forging scheme; determining a variable frequency motor working parameter according to the pressure setting value, and calculating the forging energy consumption; verifying the forging energy consumption, and when the forging energy consumption is the minimum forging energy consumption, controlling the hydraulic press to perform forging according to the variable frequency motor working parameter; obtaining the state of the forged object after forging after each forging; and determining the pressure setting value required for the next forging according to the state of the forged object after forging. The present invention reduces the energy consumption of the hydraulic press by obtaining the forging state of the forging object, monitoring and analyzing the operating state of the forging hydraulic press in real time, and controlling the output flow of the hydraulic pump by adjusting the motor speed.

[0142] In the several embodiments provided in the present application, it should be understood that the disclosed devices and methods can be implemented in other ways. The device embodiments described above are only schematic. For example, the division of the units is only a logical function division. There may be other division methods in actual implementation, such as: multiple units or components can be combined, or can be integrated into another system, or some features can be ignored or not executed. In addition, the coupling, direct coupling, or communication connection between the components shown or discussed can be through some interfaces, and the indirect coupling or communication connection of the devices or units can be electrical, mechanical or other forms.

[0143] The units described above as separate components may or may not be physically separated, and the components displayed as units may or may not be physical units; they may be located in one place or distributed on multiple network units; some or all of the units may be selected according to actual needs to achieve the purpose of the present embodiment.

[0144] In addition, all functional units in the embodiments of the present invention may be integrated into one processing unit, or each unit may be separately used as a unit, or two or more units may be integrated into one unit; the above-mentioned integrated units may be implemented in the form of hardware or in the form of hardware plus software functional units.

[0145] Those skilled in the art can understand that: all or part of the steps of implementing the above method embodiments can be completed by hardware related to program instructions, and the aforementioned program can be stored in a computer-readable storage medium. When the program is executed, it executes the steps of the above method embodiments; and the aforementioned storage medium includes: mobile storage devices, read-only memories (ROM, Read-Only Memory), random access memories (RAM, Random Access Memory), disks or optical disks, and other media that can store program codes.

[0146] Alternatively, if the above-mentioned integrated unit of the present invention is implemented in the form of a software function module and sold or used as an independent product, it can also be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the embodiment of the present invention can be essentially or partly reflected in the form of a software product that contributes to the prior art. The computer software product is stored in a storage medium and includes several instructions for a computer device (which can be a personal computer, a server, or a network device, etc.) to execute all or part of the methods described in each embodiment of the present invention. The aforementioned storage medium includes: various media that can store program codes, such as mobile storage devices, ROM, RAM, magnetic disks or optical disks.

Claims

1. A method for optimizing the energy consumption of a forging hydraulic press, characterized in that: include: Get the forging object model; Determining a forging plan according to the forging object model; Determine the pressure setting value required for the current forging through the forging plan; Determine the working parameters of the variable frequency motor according to the pressure setting value, and calculate the forging energy consumption; the working parameters of the variable frequency motor include the motor speed level corresponding to the pressure setting value, the third speed level in the return stage, the second speed level in the falling stage, the first speed level and the first acceleration in the boost stage; The forging energy consumption is verified, and when the forging energy consumption is the minimum forging energy consumption, the hydraulic press is controlled to perform forging work according to the working parameters of the variable frequency motor; After each forging is completed, the state of the forged object is obtained; The pressure setting value required for the next forging is determined according to the state of the forged object after the forging.

2. The automatic control method for optimizing energy consumption of a forging hydraulic press according to claim 1 is characterized in that: The obtaining of the forging object model and determining the forging scheme according to the forging object model includes: Acquire detection image data; Determine the model of the forged object through the detection image data; Screening the historical forging data in the database according to the forging object model to determine the historical forging data with the minimum average power consumption in each forging stage; The historical forging plans corresponding to the historical forging data with the minimum average power consumption in each forging stage are integrated to determine the forging plan.

3. The automatic control method for optimizing energy consumption of a forging hydraulic press according to claim 1, characterized in that: Determining the variable frequency motor operating parameters according to the pressure setting value includes: According to the pressure setting value p of the next forging x(i+1) , pressure setting value p x(i+1) Motor power P corresponding to motor speed level j j , motor power P at motor speed level h h , acceleration a j-h and acceleration time t a(j-h) Determine the first forging pressure adjustment interval [p a(i+1)min ,p a(i+1)max ]; According to the first forging pressure adjustment interval [p a(i+1)min ,p a(i+1)max ] Determine multiple first forging pressures p a(i+1)n ;p a(i+1)min ≤p b(i+1) ≤p a(i+1)max ; Calculate each first forging pressure p in turn a(i+1)n Adjust to the pressure setting value p x(i+1) The pressurizing energy consumption is calculated, and a first relationship curve between the first forging pressure and the pressurizing energy consumption is drawn; Determine the minimum pressurization energy consumption W according to the first relationship curve 1(i+1) and the minimum pressurization energy consumption W 1(i+1) The corresponding second forging pressure p b(i+1) ; The second forging pressure p b(i+1) The corresponding motor speed level is determined as the first speed level, and the second forging pressure p b(i+1) The corresponding acceleration is determined as the first acceleration, and the second forging pressure p b(i+1) The corresponding acceleration time is determined as the first acceleration time; The maximum first forging pressure p in the first forging pressure adjustment range a(i+1)max and the minimum first forging pressure p a(i+1)min Determine the corresponding falling start height interval [H a(i+1)min ,H a(i+1)max ]; According to the falling start height interval [H a(i+1)min ,H a(i+1)max ]Determine multiple drop start heights H a(i+1)m ; According to the second forging pressure p b(i+1) and the preset maximum falling time threshold to calculate each falling starting height H a(i+1)m The minimum falling energy consumption W 2(i+1) The corresponding falling starting height is determined as the first falling starting height, and the minimum falling energy consumption W is 2(i+1) The corresponding motor speed level is determined as the second speed level.

4. The automatic control method for optimizing energy consumption of a forging hydraulic press according to claim 3 is characterized in that: Also includes: Determine the first falling starting height as the first return height; Determine the return displacement L according to the first return height; According to the return displacement L, a relationship curve between the return power and the return time corresponding to each return motor speed level is drawn, and the return energy consumption W corresponding to each return motor speed level is calculated. 3(i) ; The return motor speed level corresponding to the minimum return energy consumption is determined as the third speed level.

5. The automatic control method for optimizing energy consumption of a forging hydraulic press according to claim 4 is characterized in that: The calculation of forging energy consumption includes: Calculate the forging energy consumption W required for forging work i+1 (i+1) ; IN (i+1) =k1×W 1(i+1) +k2×W 2(i+1) +k3×W 3(i) ; Among them, k1, k2 and k3 are all influencing factors, and the values ​​of influencing factors k1, k2 and k3 are determined according to the difference between the actual energy consumption and the predicted energy consumption in the current forging work i.

6. The automatic control method for optimizing energy consumption of a forging hydraulic press according to claim 5 is characterized in that: The verifying of the forging energy consumption includes: From the first forging pressure adjustment interval [p a(i+1)min ,p a(i+1)max ] randomly select one or more first forging pressures p a(i+1)q , calculate the one or more first forging pressures p a(i+1)q The corresponding one or more verification forging energy consumption W (i+1)q ; The one or more verification forging energy consumption W (i+1)q Respectively with forging energy consumption W (i+1) Make a comparison; When forging energy consumption W (i+1) When it is the minimum value, determine the forging energy consumption W (i+1) Minimum forging energy consumption; Otherwise, calculate each first forging pressure p a(i+1)n The corresponding forging energy consumption W (i+1)n , multiple forging energy consumption W (i+1)n The minimum value of is determined as the final forging energy consumption W (i+1) .

7. The automatic control method for optimizing energy consumption of a forging hydraulic press according to claim 5, characterized in that: Also includes: After each hydraulic work is completed, the influencing factors k1, k2 and k3 are corrected based on the difference between the actual energy consumption and the predicted energy consumption; the actual energy consumption includes the actual pressurization energy consumption in the pressurization stage, the actual falling energy consumption in the falling stage and the actual return energy consumption in the return stage; the predicted energy consumption includes the minimum pressurization energy consumption in the pressurization stage, the minimum falling energy consumption in the falling stage and the minimum return energy consumption in the return stage.

8. The automatic control method for optimizing energy consumption of a forging hydraulic press according to claim 1, characterized in that: The step of determining the pressure setting value required for the next forging according to the state of the forged object after forging comprises: Compare the state of the forged object after forging with the state of the forged object before forging to determine the actual forging progress; Compare the actual forging progress with the expected forging progress to determine whether the error condition is met; If yes, the pressure setting value for the next forging is retrieved through the forging plan; If not, the pressure setting value for the next forging is determined according to the state of the forged object after forging.

9. The automatic control method for optimizing energy consumption of a forging hydraulic press according to claim 1, characterized in that: Also includes: During the forging process, the first warning score is calculated based on the real-time pressure, stamping time and hydraulic oil temperature; When the first warning score is greater than or equal to the preset warning score threshold, the current forging is ended and the hydraulic press is controlled to return.

10. An automatic control system for optimizing energy consumption of a forging hydraulic press, used to implement the automatic control method for optimizing energy consumption of a forging hydraulic press as claimed in any one of claims 1 to 9, characterized in that: include: A data acquisition module, used to obtain the model of the forging object; A forging scheme generating module, used for determining a forging scheme according to the forging object model; A first pressure value adjustment module, used to determine the pressure setting value required for the current forging according to the forging scheme; A motor working parameter setting module, used to determine the working parameters of the variable frequency motor according to the pressure setting value and calculate the forging energy consumption; the working parameters of the variable frequency motor include the motor speed level corresponding to the pressure setting value, the third speed level in the return stage, the second speed level in the falling stage, the first speed level and the first acceleration in the boost stage; An energy consumption verification module, used to verify the forging energy consumption, and when the forging energy consumption is the minimum forging energy consumption, control the hydraulic press to perform forging work according to the working parameters of the variable frequency motor; The second pressure value adjustment module is used to obtain the state of the forged object after each forging is completed; and determine the pressure setting value required for the next forging according to the state of the forged object after forging.

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