An automatic control system and control method for energy consumption optimization of a forging hydraulic press

Abstract

The present invention discloses an automatic control system and control method for energy consumption optimization of a forging hydraulic press. The method includes: obtaining the model of the forging object; determining a forging plan according to the model of the forging object; determining the pressure set value required for the current forging through the forging plan; determining the operating parameters of the variable-frequency motor according to the pressure set value and calculating the forging energy consumption; verifying the forging energy consumption. When the forging energy consumption is the minimum forging energy consumption, controlling the hydraulic press to perform forging work according to the operating parameters of the variable-frequency motor; after each forging is completed, obtaining the state of the forged object; determining the pressure set value required for the next forging according to the state of the forged object. 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 adjusting the output flow of the hydraulic pump by controlling the motor speed.

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 the 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 processing of metal materials. However, in the actual use process, traditional energy consumption management methods often rely on experience or fixed control strategies, and are adjusted manually, lacking data-driven intelligent decision-making support and being difficult to adapt to complex and changeable working conditions. At the same time, during the long-term operation of the hydraulic press, due to reasons such as wear and leakage, it is easy to cause an increase in energy consumption and a decrease in production efficiency.

[0003] Therefore, there are defects in the existing technology and urgent improvements are needed. 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 obtain the forging state of the forging object, and real-time monitor and analyze the operating state of the forging hydraulic press, and control the output flow of the hydraulic pump by adjusting the motor speed to reduce the energy consumption of the hydraulic press.

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

[0006] Obtain the forging object model;

[0007] Determine the forging plan according to the forging object model;

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

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

[0010] Verify the forging energy consumption. 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;

[0011] After each forging is completed, obtain the state of the forging object after forging;

[0012] Determine the pressure set value required for the next forging according to the state of the forging object after forging.

[0013] In this solution, the obtaining of the forging object model and the determination of the forging plan according to the forging object model include:

[0014] Obtain the detected image data;

[0015] Determine the forging object model through the detected image data;

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

[0017] Integrate the historical forging schemes corresponding to the historical forging data with the minimum average power consumption at each forging stage to determine the forging scheme.

[0018] In this solution, the determining of the working parameters of the variable-frequency motor according to the pressure set value includes:

[0019] According to the pressure set value p for the next forging x(i+1) , the motor power P corresponding to the motor speed level j of the pressure set value p x(i+1) , the motor power P corresponding to the motor speed level h of the motor power P j , the acceleration a h , and the acceleration time t j-h to determine the first forging pressure adjustment range [p a(j-h) , p a(i+1)min when the hydraulic press contacts the forging object; a(i+1)max

[0020] According to the first forging pressure adjustment range [p a(i+1)min , p a(i+1)max to determine a plurality of first forging pressures p a(i+1)n ; p a(i+1)min ≤ p b(i+1) ≤ p a(i+1)max ;

[0021] Calculate the pressurization energy consumption for adjusting each first forging pressure p a(i+1)n to the pressure set value p x(i+1) in turn, and draw the first relationship curve between the first forging pressure and the pressurization energy consumption;

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

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

[0024] Adjust the maximum first forging pressure p according to the first forging pressure adjustment range a(i+1)max and the minimum first forging pressure p a(i+1)min to determine the corresponding falling start height range [H a(i+1)min , H a(i+1)max ;

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

[0026] Calculate the falling energy consumption of each falling start height H according to the second forging pressure p b(i+1) and the preset maximum falling time threshold, and determine the falling start height corresponding to the minimum falling energy consumption W a(i+1)m as the first falling start height, and determine the motor speed level corresponding to the minimum falling energy consumption W 2(i+1) as the second speed level. 2(i+1)

[0027] In this solution, it further includes:

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

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

[0030] Draw the relationship curve of the return power and return time corresponding to each return motor speed level according to the return displacement L, and calculate the return energy consumption W 3(i) ;

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

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

[0033] Calculate the forging energy consumption W required for the 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 the influencing factors k1, k2, and k3 are determined according to the difference value 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] Randomly select one or more first forging pressures p from the first forging pressure adjustment range [p a(i+1)min , p a(i+1)max , and calculate the corresponding one or more verification forging energy consumptions W a(i+1)q of the one or more first forging pressures p a(i+1)q ; (i+1)q

[0038] Compare the one or more verification forging energy consumptions W (i+1)q with the forging energy consumption W (i+1) respectively;

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

[0040] Otherwise, calculate the forging energy consumption W a(i+1)n corresponding to each first forging pressure p respectively, and determine the minimum value among the multiple forging energy consumptions W (i+1)n as the final forging energy consumption W (i+1)n . (i+1)

[0041] In this solution, it also includes:

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

[0043] In this solution, the determination of 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 so, retrieve the pressure setting value for the next forging through the forging plan;

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

[0048] In this solution, it also includes: ​​

[0049] During the forging process, calculate the first warning score 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, end the current forging and control the hydraulic press to return.

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

[0052] A data acquisition module for acquiring the model of the forging object;

[0053] A forging plan generation module for determining a forging plan according to the model of the forging object;

[0054] A first pressure value adjustment module for determining the required pressure setting value for the current forging through the forging plan;

[0055] A motor operating parameter setting module for determining the operating parameters of the variable-frequency motor according to the pressure setting value and calculating the forging energy consumption; the operating parameters of the variable-frequency motor include the motor speed level corresponding to the pressure setting value, the third speed level during the return stage, the second speed level during the falling stage, the first speed level during the boosting stage, and the first acceleration;

[0056] An energy consumption verification module for verifying the forging energy consumption. When the forging energy consumption is the minimum forging energy consumption, control the hydraulic press to perform forging work according to the operating parameters of the variable-frequency motor;

[0057] A second pressure value adjustment module for, after each forging is completed, acquiring the state of the forged forging object; and determining the required pressure setting value for the next forging according to the state of the forged forging object.

[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 the energy consumption of a forging hydraulic press. When the program for the automatic control method for optimizing the energy consumption of a forging hydraulic press is executed by a processor, the steps of the above-mentioned automatic control method for optimizing the energy consumption of a forging hydraulic press are implemented.

[0059] The present invention discloses an automatic control system and method for optimizing the energy consumption of a forging hydraulic press. The method includes: obtaining the model of the forging object; determining the forging plan according to the model of the forging object; determining the pressure setting value required for the current forging through the forging plan; determining the operating parameters of the variable-frequency motor according to the pressure setting value, and calculating the forging energy consumption; verifying the forging energy consumption. When the forging energy consumption is the minimum forging energy consumption, controlling the hydraulic press to perform forging work according to the operating parameters of the variable-frequency motor; after each forging is completed, obtaining the state of the forged forging object; and determining the pressure setting value required for the next forging according to the state of the forged forging object. 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 adjusting the motor speed to control the output flow of the hydraulic pump. Description of the Drawings

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

[0061] Figure 2 The flowchart of the forging plan generation method provided by the present invention is shown;

[0062] Figure 3 The flowchart of the forging energy consumption verification method provided by the present invention is shown;

[0063] Figure 4 The block diagram of an automatic control system for optimizing the energy consumption of a forging hydraulic press provided by the present invention is shown. Detailed Embodiments

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

[0065] Many specific details are set forth in the following description in order to fully understand the present invention. However, the present invention can also be implemented in other ways different from those described herein. Therefore, the protection scope of the present invention is not limited by the specific embodiments disclosed below.

[0066] Figure 1 The flowchart of an automatic control method for optimizing the energy consumption of a forging hydraulic press provided by the present invention is shown.

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

[0068] S102, obtaining the model of the forging object;

[0069] S104, Determine the forging plan according to the forging object model;

[0070] S106, Determine the pressure setting value required for the current forging according to the forging plan;

[0071] S108, Determine the operating parameters of the variable-frequency motor according to the pressure setting value, and calculate the forging energy consumption; the operating parameters of the variable-frequency motor include the motor speed level corresponding to the pressure setting value, the third speed level during the return stroke stage, the second speed level during the falling stage, the first speed level and the first acceleration during the pressurization stage;

[0072] S110, Verify the forging energy consumption. When the forging energy consumption is the minimum forging energy consumption, control the hydraulic press to perform forging work according to the operating parameters of the variable-frequency motor;

[0073] S112, After each forging is completed, obtain the state of the forged object;

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

[0075] According to the embodiments of the present invention, the detection image data of the forging object is obtained through devices such as a camera device. By analyzing the detection image data, the forging object model of the forging object is determined. The historical forging data of the same forging object model is screened from the 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 plans are extracted and integrated to determine the forging plan for the current forging object.

[0076] A forging process consists of a return stroke stage, a falling stage, and a forging stage. The forging stage includes a pressurization stage and a stamping stage. When the hydraulic press is first started for forging, the hydraulic press falls from the top, that is, the return stroke stage is not included. The pressure setting value that enables the forging object to meet the expected forging conditions in the next forging process of the hydraulic press falling is determined according to the forging plan. According to the pressure setting value and the maximum motor acceleration time of the pressurization stage preset by the system, the first forging pressure adjustment range when the hydraulic press contacts the forging object is determined. Multiple first forging pressures are selected from the first forging pressure adjustment range, 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 plotted. The minimum pressurization energy consumption and the corresponding second forging pressure are determined through the first relationship curve. The operating parameters of the variable-frequency motor in the pressurization stage are determined through the second forging pressure, including the first speed level, the first acceleration, and the first acceleration time. Then, through the first forging pressure adjustment range [p a(i+1)min , p a(i+1)max and the historical hydraulic data are analyzed to determine the falling start height range [H a(i+1)min , Ha(i+1)max Calculate the first falling height and the second rotational speed level corresponding to the minimum falling energy consumption when the hydraulic press stably meets the second forging pressure before contacting the forging object within the falling height range, and determine the operating parameters of the variable-frequency motor in the falling stage. Then, determine the third rotational speed level corresponding to the minimum return energy consumption in the return stage based on the first falling height, and determine the operating parameters of the variable-frequency motor in the return stage.

[0077] In addition, to ensure the forging energy consumption W (i+1) is the minimum forging energy consumption, randomly select one or more first forging pressures p a(i+1)min , p a(i+1)max within the first forging pressure adjustment range [p a(i+1)q , calculate the corresponding verified forging energy consumption W (i+1)q . When the forging energy consumption W (i+1) is less than each verified forging energy consumption W (i+1)q , determine that the forging energy consumption W (i+1) is the minimum forging energy consumption. During the next forging process, adjust the motor speed of the variable-frequency motor according to the operating parameters of the variable-frequency motor in the return stage, the falling stage, and the pressurizing stage respectively, so as to ensure that the energy consumption of each forging process is the minimum energy consumption.

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

[0079] Figure 2 The flowchart of the forging plan generation method provided by the present invention is shown.

[0080] As Figure 2 shown, according to the embodiment of the present invention, obtaining the forging object model and determining the forging plan according to the forging object model includes:

[0081] S202, obtaining the detected image data;

[0082] S204, determining the forging object model through the detected 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 the historical forging plans corresponding to the historical forging data with the minimum average power consumption in each forging stage, and determining the forging plan.

[0085] It should be noted that during the forging process of the hydraulic press, the system will collect various forging parameters generated (including the forging object model, motor speed level, acceleration, acceleration time, and forging energy consumption during the return, falling, and pressurizing stages of the hydraulic press, etc.), generate historical forging data, and store it in the database. After determining the forging object model of the forging object, the historical forging data in the database is screened according to the forging object model, and the average power consumption of the historical forging data of each forging object model with the same type is calculated in turn for each forging stage. The historical forging data with the minimum average power consumption in each forging stage is determined, and the corresponding forging parameters and historical forging plans are extracted and integrated to determine the forging plan for the current forging object.

[0086] Among them, the forging stage of the forging object is determined by the system according to the change of the forging object state and other methods. For example, when multi-sided forging of the forging object is required, the forging stage is divided according to the forging requirements of each forging surface.

[0087] According to the embodiments of the present invention, the operating parameters of the variable-frequency motor are determined according to the pressure setting value, including:

[0088] According to the pressure setting value p for the next forging x(i+1) , the pressure setting value p x(i+1) , the motor power P corresponding to the motor speed level j j , the motor power P of the motor speed level h h , the acceleration a j-h and the acceleration time t a(j-h) to determine the first forging pressure adjustment range [p a(i+1)min , p a(i+1)max when the hydraulic press contacts the forging object;

[0089] According to the first forging pressure adjustment range [p a(i+1)min , p a(i+1)max , a plurality of first forging pressures p a(i+1)n are determined; p a(i+1)min ≤p b(i+1) ≤p a(i+1)max ;

[0090] Calculate in turn the pressurization energy consumption for each first forging pressure p a(i+1)n to be adjusted to the pressure setting value p x(i+1) , and draw the first relationship curve between the first forging pressure and the pressurization energy consumption;

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

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

[0093] According to the maximum first forging pressure p a(i+1)max and the minimum first forging pressure p a(i+1)min in the first forging pressure adjustment range, determine the corresponding starting falling height range [H a(i+1)min , H a(i+1)max ;

[0094] According to the starting falling height range [H a(i+1)min , H a(i+1)max , determine multiple starting falling heights H a(i+1)m ;

[0095] According to the second forging pressure p b(i+1) and the preset maximum falling time threshold, calculate the falling energy consumption of each starting falling height H a(i+1)m respectively. Determine the starting falling height corresponding to the minimum falling energy consumption W 2(i+1) as the first starting falling height, and determine the motor speed level corresponding to the minimum falling energy consumption W 2(i+1) 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 frequency conversion motor speed level and increase the hydraulic pressure to meet the forging pressure of the forging object. The system defaults to enter 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 set value p x(i+1) for the next forging and the motor power P j corresponding to the motor speed level j. Combining the motor parameters of the frequency conversion motor, determine the maximum first forging pressure p x(i+1) and the minimum first forging pressure p a(i+1)max that can adjust the hydraulic press pressure to the pressure set value p a(i+1)min before the preset maximum motor acceleration time of the system through the system preset pressurization pressure change calculation method (such as through historical data comparison, model calculation, etc.). Determine the first forging pressure adjustment range [p a(i+1)min , p a(i+1)max , and select multiple first forging pressures p a(i+1)min , p a(i+1)max from the first forging pressure adjustment range [p a(i+1)n. Determine the first forging pressure p a(i+1)n The corresponding motor speed level h and motor power P h , acceleration a h-j and acceleration time t a(h-j) . Divide it into several small time periods according to the acceleration time. Determine the energy consumption of each time period according to 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. Add up the energy consumption of all time periods to determine the pressurization energy consumption when the hydraulic press pressure increases from the first forging pressure to the pressure set value. Establish a coordinate axis with the first forging pressure on the abscissa and the pressurization energy consumption on the ordinate. Input each first forging pressure and the corresponding pressurization energy consumption into this coordinate axis, connect the coordinate points generated by adjacent first forging pressures, and perform smoothing processing to determine the first relationship curve between the first forging pressure and the pressurization energy consumption. Determine the minimum value of the pressurization energy consumption W in the first relationship curve 1(i+1) , and the corresponding first forging pressure is the second forging pressure p b(i+1) .

[0098] When the hydraulic press starts to fall, since the motor has just started working, affected by the internal load of the hydraulic press (such as the resistance generated by the liquid flow between the internal components of the hydraulic press), there will be a certain pressure fluctuation. If the hydraulic press needs to frequently return to the highest position for the next operation, then this may increase the working time, reduce the working efficiency and increase the energy consumption. Through the maximum first forging pressure p a(i+1)max and the minimum first forging pressure p a(i+1)min in the first forging pressure adjustment range, combined with historical hydraulic data for analysis, respectively determine the maximum falling start height H a(i+1)max for the hydraulic press to eliminate pressure fluctuations and meet the stable pressure drop before contacting the forging object a(i+1)min and the minimum falling start height H a(i+1)min , and determine the falling start height range [H a(i+1)max . Among them, the greater the first forging pressure, the higher the required falling start height. Select multiple falling start heights H a(i+1)min from the falling start height range [H a(i+1)max according to the system preset height interval a(i+1)m , and respectively determine the motor speed level and the falling time for each falling start height H a(i+1)m to adjust the hydraulic press pressure to the second forging pressure p b(i+1) before the hydraulic press contacts the forging object, and calculate the product of the two to determine the falling energy consumption for each falling start height H a(i+1)m .

[0099] According to the embodiments of the present invention, it further includes:

[0100] Determine the first falling start height as the first return stroke height;

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

[0102] Draw a relationship curve of the return power and return time corresponding to each return motor speed level according to the return stroke displacement L, and calculate the return energy consumption W corresponding to each return motor speed level 3(i) ;

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

[0104] It should be noted that the return stroke displacement L is determined by the first return stroke height and the return hydraulic cavity specifications, the return time corresponding to each return motor speed level is calculated by determining the displacement speed corresponding to the return stroke displacement L and the return motor speed level, the corresponding relationship between the return power and return time corresponding to each return motor speed level is determined, the return power and return time under the same return motor speed level are multiplied to determine the return energy consumption corresponding to this 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 stroke stage.

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

[0106] Calculate the forging energy consumption W required for the 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] Wherein, k1, k2 and k3 are all influencing factors, and the values of the influencing factors k1, k2 and k3 are determined according to the difference value 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, falling stage and return stroke stage is 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 suffered by the hydraulic press during operation, etc.; the falling stage and return stroke stage are mainly affected by the inertial load generated at the start of operation, the friction load between the components of the hydraulic press, the air resistance and liquid resistance suffered by the hydraulic press during operation, the temperature of the hydraulic oil, the leakage amount and other parameters; by setting the influencing factors k1, k2 and k3 to correct 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 stroke stage respectively, the forging energy consumption required for the forging work i + 1 is determined.

[0110] Figure 3 The flowchart of the forging energy consumption verification method provided by the present invention is shown;

[0111] As Figure 3 shown, according to the embodiments of the present invention, verifying the forging energy consumption includes:

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

[0113] S304, compare one or more verification forging energy consumptions W (i+1)q with the forging energy consumption W (i+1) respectively;

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

[0115] S308, otherwise, calculate the forging energy consumption W a(i+1)n corresponding to each first forging pressure p (i+1)n respectively, and determine the minimum value among multiple forging energy consumptions W (i+1)n as the final forging energy consumption W (i+1) .

[0116] It should be noted that while calculating the forging energy consumption W b(i+1) corresponding to the second forging pressure p (i+1) , randomly select one or more first forging pressures p a(i+1)min , p a(i+1)max from the first forging pressure adjustment range [p a(i+1)q , calculate one or more verification forging energy consumptions W (i+1)q corresponding thereto, and use them to verify the forging energy consumption W (i+1) . The calculation methods of the verification forging energy consumption W (i+1)q and the forging energy consumption W (i+1) are the same, and the values of the influencing factors k1, k2, and k3 are also the same. When there is a verification forging energy consumption W (i+1)q less than the forging energy consumption W (i+1) , determine that the second forging pressure p b(i+1) is not the optimal forging pressure when the hydraulic press contacts the forging object. By performing a complete calculation on all the first forging pressures, determine the minimum value among multiple forging energy consumptions W (i+1)n as the final forging energy consumption W (i+1), according to the final forging energy consumption W (i+1) Adjust the motor control parameters (including speed level, acceleration, acceleration time, etc.) for the pressurization stage, falling stage, and return stroke stage.

[0117] According to the embodiments of the present invention, it further includes:

[0118] After each hydraulic operation is completed, correct the influencing factors k1, k2, and k3 based on the difference value 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 stroke energy consumption in the return stroke 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 stroke energy consumption in the return stroke stage.

[0119] It should be noted that the various parameters inside the hydraulic press will change according to the usage time of the hydraulic press. For example, the longer the working time and the higher the hydraulic oil temperature, the smaller the viscosity and the better the fluidity, which may lead to a decrease in system pressure, etc. Obtain the actual energy consumption of the current hydraulic operation in the pressurization stage, falling stage, and return stroke stage through the energy consumption monitoring module, compare it with the corresponding predicted energy consumption, correct the influencing factors k1, k2, and k3 according to the difference value between the two, and calculate the hydraulic energy consumption of the next hydraulic operation through the corrected influencing factors k1, k2, and k3 to determine the corresponding motor control parameters.

[0120] According to the embodiments of the present invention, determining the pressure setting value required for the next forging based on 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 so, retrieve the pressure setting value for the next forging through the forging plan;

[0124] If not, determine the pressure setting value for the next forging based on the state of the forged object after forging.

[0125] It should be noted that, affected by various factors, during the forging process of the forging object by the hydraulic press according to the set motor control parameters, the forging object may not achieve the expected forging effect. By obtaining the state of the forging object after forging (determined by detecting images, the final height after the hydraulic press stamping ends, etc.), calculating the actual forging progress, determining the progress difference between the actual forging progress and the expected forging progress, when the progress difference is less than the preset progress difference threshold, the error condition is satisfied; otherwise, the error condition is not satisfied. 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 satisfied, the pressure setting value for the next forging is retrieved according to the forging sequence in the forging plan; when the error condition is not satisfied, the pressure setting value for the next forging is determined according to the state of the forging object after forging and the state of the forging object corresponding to the expected forging progress, so that the forging effect of the forging object after forging meets the expected forging effect.

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

[0127] During the forging process, calculate the first warning score according to 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, end the current forging and control the hydraulic press 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 a pressure sensor, a timer, and a temperature sensor, and the real-time pressure, stamping time, and hydraulic oil temperature are respectively multiplied by the corresponding influence weights, 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, there is a risk in the current forging work, and the current forging work is forced to end. The motor control parameters for the next forging work are determined according to the state of the forging object, and the hydraulic press is controlled to return. Among them, the preset warning score threshold is set by those skilled in the art according to actual needs.

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

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

[0133] A data acquisition module for acquiring the forging object model;

[0134] A forging plan generation module, configured to determine a forging plan according to the forging object model;

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

[0136] A motor operating parameter setting module, configured to determine the operating parameters of the variable-frequency motor according to the pressure setting value and calculate the forging energy consumption; the operating 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 in the boosting stage, and the first acceleration;

[0137] An energy consumption verification module, configured to verify the forging energy consumption. When the forging energy consumption is the minimum forging energy consumption, control the hydraulic press to perform forging work according to the operating parameters of the variable-frequency motor;

[0138] A second pressure value adjustment module, configured to obtain the state of the forged forging object after each forging; determine the pressure setting value required for the next forging according to the state of the forged forging object.

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

[0140] The information (including but not limited to user equipment information, user personal information, etc.), data (including but not limited to data for analysis, stored data, displayed data, etc.), and signals (including but not limited to signals transmitted between the user terminal and other devices) 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 need to comply with relevant laws, regulations, and standards of relevant countries and regions. For example, the "forging object model", "historical forging data", etc. involved in this disclosure are obtained under full authorization.

[0141] The present invention discloses an automatic control system and a control method for optimizing the energy consumption of a forging hydraulic press. The method includes: obtaining the model of the forging object; determining a forging plan according to the model of the forging object; determining the pressure setting value required for the current forging through the forging plan; determining the operating parameters of the variable-frequency motor according to the pressure setting value, and calculating the forging energy consumption; verifying the forging energy consumption. When the forging energy consumption is the minimum forging energy consumption, controlling the hydraulic press to perform forging work according to the operating parameters of the variable-frequency motor; after each forging is completed, obtaining the state of the forged forging object; determining the pressure setting value required for the next forging according to the state of the forged forging object. The present invention obtains the forging state of the forging object, monitors and analyzes the operating state of the forging hydraulic press in real time, and controls the output flow of the hydraulic pump by adjusting the motor speed, thereby reducing the energy consumption of the hydraulic press.

[0142] In 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 merely illustrative. For example, the division of the units is only a logical function division. In actual implementation, there may be other division methods. For example, 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 various components shown or discussed may be through some interfaces. The indirect coupling or communication connection of the devices or units may be electrical, mechanical, or other forms.

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

[0144] In addition, in each embodiment of the present invention, the various functional units may all be integrated in one processing unit, or each unit may be separately used as a unit, or two or more units may be integrated in one unit; the above integrated units may be implemented in the form of hardware, or in the form of a combination of hardware and software functional units.

[0145] Those of ordinary skill in the art will understand that all or part of the steps to implement the above method embodiments can be completed by hardware related to program instructions. The aforementioned program can be stored in a computer-readable storage medium. When the program is executed, it performs the steps including those of the above method embodiments; and the aforementioned storage medium includes: removable storage devices, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical discs, etc., various media that can store program codes.

[0146] Alternatively, if the above integrated unit of the present invention is implemented in the form of a software functional module and sold or used as an independent product, it can also be stored in a computer-readable storage medium. Based on such an understanding, the technical solution of the embodiments of the present invention, in essence or the part that contributes to the prior art, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to enable 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 the various embodiments of the present invention. And the aforementioned storage medium includes: removable storage devices, ROM, RAM, magnetic disks, or optical discs, etc., various media that can store program codes.

Claims

1. An automatic control method for optimizing the energy consumption of a forging hydraulic press, characterized in that, Including: Obtain the forging object model; Determine the forging plan according to the forging object model; Determine the pressure setting value required for the current forging through the forging plan; Determine the operating parameters of the variable-frequency motor according to the pressure setting value, and calculate the forging energy consumption; the operating parameters of the variable-frequency motor include the motor speed level corresponding to the pressure setting value, the third speed level in the return stroke stage, the second speed level in the falling stage, the first speed level in the boosting stage, and the first acceleration; Verify the forging energy consumption. When the forging energy consumption is the minimum forging energy consumption, control the hydraulic press to perform forging work according to the operating parameters of the variable-frequency motor; After each forging is completed, obtain the state of the forged forging object; Determine the pressure setting value required for the next forging according to the state of the forged forging object; The determining the operating parameters of the variable-frequency motor according to the pressure setting value includes: Set the pressure setting value p for the next forging x(i+1) and the pressure setting value p x(i+1) correspond to the motor power P of the motor speed level j j and the motor power P of the motor speed level h h and the acceleration a j-h and the acceleration time t a(j-h) Determine the first forging pressure adjustment range [p a(i+1)min , p a(i+1)max when the hydraulic press contacts the forging object; Determine a plurality of first forging pressures p according to the first forging pressure adjustment range [p a(i+1)min , p a(i+1)max ; where p a(i+1)n ; p a(i+1)min ≤ p a(i+1)n ≤ p a(i+1)max ; Calculate each first forging pressure p in sequence a(i+1)n Adjust to the pressure set value p x(i+1) for the pressurization energy consumption, and plot the first relationship curve between the first forging pressure and the pressurization energy consumption; 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) corresponding second forging pressure p b(i+1) ; Determine the motor speed level corresponding to the second forging pressure p b(i+1) as the first speed level, determine the acceleration corresponding to the second forging pressure p b(i+1) as the first acceleration, and determine the acceleration time corresponding to the second forging pressure p b(i+1) as the first acceleration time; According to 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 to determine the corresponding starting height range of the fall [H a(i+1)min , H a(i+1)max ; Determine a plurality of starting falling heights H according to the starting falling height range [H a(i+1)min , H a(i+1)max ; a(i+1)m ; Calculate the falling energy consumption of each falling start height H according to the second forging pressure p b(i+1) and the preset maximum falling time threshold respectively, and determine the falling start height corresponding to the minimum falling energy consumption W a(i+1)m as the first falling start height, and determine the motor speed level corresponding to the minimum falling energy consumption W 2(i+1) as the second speed level. 2(i+1) ​ 2. The automatic control method for optimizing the energy consumption of a forging hydraulic press according to claim 1, wherein, The obtaining the forging object model and determining the forging plan according to the forging object model includes: Obtain the detection image data; Determine the forging object model through the detection image data; Screen the historical forging data in the database according to the forging object model, and determine the historical forging data with the minimum average power consumption in each forging stage; Integrate the historical forging plans corresponding to the historical forging data with the minimum average power consumption in each forging stage to determine the forging plan.

3. The automatic control method for optimizing the energy consumption of a forging hydraulic press according to claim 1, characterized in that Also include: Determine the first return height as the first falling start height; Determine the return displacement L according to the first return height; Draw the relationship curve of return power and return time corresponding to each return motor speed level according to the return displacement L, and calculate the return energy consumption W corresponding to each return motor speed level 3(i) ; Determine the third speed level as the return motor speed level corresponding to the minimum return energy consumption.

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

5. The automatic control method for optimizing the energy consumption of a forging hydraulic press according to claim 4, characterized in that The verifying the forging energy consumption includes: Randomly select one or more first forging pressures p from the first forging pressure adjustment range [p a(i+1)min , p a(i+1)max , and calculate one or more verification forging energy consumptions W corresponding to the one or more first forging pressures p a(i+1)q ; a(i+1)q (i+1)q ;​ Compare the one or more verified forging energy consumptions W (i+1)q with the forging energy consumption W (i+1) respectively; When the forging energy consumption W (i+1) is at its minimum value, determine the forging energy consumption W (i+1) as the minimum forging energy consumption; Conversely, calculate the forging energy consumption W corresponding to each first forging pressure p a(i+1)n respectively (i+1)n , and determine the minimum value among multiple forging energy consumptions W as the final forging energy consumption W (i+1)n . (i+1) .

6. The automatic control method for optimizing the energy consumption of a forging hydraulic press according to claim 4, characterized in that, Also include: After each hydraulic work is completed, correct the influencing factors k1, k2, and k3 based on the difference value 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 stroke 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 stroke stage.

7. The automatic control method for optimizing the energy consumption of a forging hydraulic press according to claim 1, characterized in that, The determining the pressure setting value required for the next forging according to the state of the forged forging object includes: Compare the state of the forged forging object with the state of the forging 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 so, retrieve the pressure setting value for the next forging through the forging plan; If not, determine the pressure setting value for the next forging according to the state of the forged forging object.

8. The automatic control method for optimizing the energy consumption of a forging hydraulic press according to claim 1, characterized in that, Also include: During forging, calculate the first warning score according to 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, end the current forging and control the hydraulic press to return.

9. An automatic control system for optimizing the energy consumption of a forging hydraulic press, which is used to implement the automatic control method for optimizing the energy consumption of the forging hydraulic press according to any one of claims 1-8, characterized in that, Including: A data acquisition module for obtaining the forging object model; A forging plan generation module for determining the forging plan according to the forging object model; The first pressure value adjustment module is used to determine the pressure setting value required for the current forging through the forging plan; The motor operating parameter setting module is used to determine the operating parameters of the variable-frequency motor according to the pressure setting value and calculate the forging energy consumption; the operating parameters of the variable-frequency motor include the motor speed level corresponding to the pressure setting value, the third speed level in the return stroke stage, the second speed level in the falling stage, the first speed level in the boosting stage, and the first acceleration; The energy consumption verification module is used to verify the 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 operating 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; 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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