Direct-drive eccentric forging unit

Abstract

The invention discloses a direct-drive eccentric forging unit which comprises a box body, a torque motor, a flywheel, an eccentric shaft, a ram and a servo return stroke system. The torque motor directly drives the eccentric shaft through the expansion sleeve, the flywheel releases impact energy, the ram drives the forging die through the connecting rod to complete forging, and the servo return stroke system achieves dynamic resetting of the ram. By means of the direct drive and energy storage technology, the problems that traditional equipment is high in energy consumption and low in precision are solved, the forging frequency reaches 2000 times per minute, the precision of forgings is smaller than or equal to 0.05 mm, and the device is suitable for production of automobile and aerospace precision forgings.

Description

Technical Field

[0001] The invention relates to the technical field of forging equipment, in particular to a direct-driven eccentric forging unit. Background Art

[0002] Traditional forging equipment uses hydraulic or mechanical drive, which has the following defects: (1) large energy loss, low efficiency of the hydraulic system, and long mechanical transmission chain resulting in insufficient overall energy efficiency; (2) transmission components (such as gears and belts) are prone to wear, with short maintenance cycles and high costs; (3) high-frequency forging causes significant inertial impact, and the size deviation of forgings is ≥0.1mm, which makes it difficult to meet the needs of precision forgings. Therefore, there is an urgent need for a forging equipment that can reduce energy consumption and improve forging accuracy.

[0003] The present invention solves the above-mentioned problems through the coordinated design of torque motor direct drive, flywheel energy storage and servo return system, thereby achieving a comprehensive improvement in forging efficiency, precision and reliability. Summary of the invention

[0004] The object of the present invention is to provide a direct-drive eccentric forging unit to solve the problems raised in the background technology.

[0005] To achieve the above-mentioned purpose, the present invention provides the following technical solutions: a direct-drive eccentric forging unit, comprising a housing and a servo return system; the housing is a high-strength cast steel integrated structure, and a torque motor mounting seat and an eccentric shaft support bearing are arranged inside the housing; a torque motor is fixed on the mounting seat of the housing, and the output end of the torque motor is keylessly connected to the eccentric shaft through a clamping sleeve to directly drive the eccentric shaft to rotate; a flywheel is installed at the driving end of the eccentric shaft, and the flywheel is made of a nickel-based alloy, and its moment of inertia is adjusted by increasing or decreasing the counterweight block; the eccentricity of the eccentric shaft is 5-50mm, its surface is nitrided, and is connected to the ram through a needle bearing; the ram is arranged on a linear guide rail inside the housing, with a stroke accuracy of ±0.01mm, and the front end is connected to the connecting rod through a ball hinge; shock-absorbing washers are arranged at both ends of the connecting rod, one end of which is connected to the ram, and the other end drives the forging die; the servo return system integrates a high-precision servo valve and a servo cylinder, monitors the ram position in real time, and realizes dynamic reset through closed-loop control, and the reset response time is ≤10ms.

[0006] Preferably, the expansion sleeve adopts a conical locking structure to achieve a keyless connection between the flywheel and the eccentric shaft.

[0007] Preferably, the forging die is modular in design, and a nickel-based alloy layer is welded on the surface to improve wear resistance.

[0008] Preferably, the servo return system feeds back the displacement of the ram in real time through a position sensor, and controls the reset speed of the ram in conjunction with the servo cylinder.

[0009] The working process of the present invention is as follows: The torque motor of the present invention is fixed on the box body. When the torque motor is started, the torque motor drives the eccentric shaft to rotate through the expansion sleeve. The eccentric shaft drives the ram to reciprocate, and the ram drives the forging die through the connecting rod to complete forging; the servo return system monitors the position of the ram in real time and realizes dynamic reset through closed-loop control.

[0010] The beneficial effects of the present invention are as follows: (1) In the present invention, the direct drive of the torque motor reduces energy loss, and the comprehensive energy efficiency is increased by ≥30%; the flywheel energy storage system recovers impact energy, and the peak power demand is reduced by 40%.

[0011] (2) The servo return system of the present invention dynamically compensates for inertial errors. The forging frequency is stably up to 2000 times per minute, and the dimensional accuracy of the forgings is ≤0.05 mm, which is better than that of traditional equipment.

[0012] (3) The modular forging die and flywheel of the present invention support quick replacement, the downtime is reduced by 70%, and self-lubricating bearings are used inside the box body, and the maintenance cycle is extended to 5000 hours. Description of the Drawings

[0013] Figure 1 is the front view structural schematic diagram of the present invention; Figure 2 is the side view structural schematic diagram of the present invention; In the figure: 1 - torque motor, 2 - box body, 3 - flywheel, 4 - expansion sleeve, 5 - eccentric shaft, 6 - ram, 7 - connecting rod, 8 - servo return system, 9 - forging die. Detailed Embodiments

[0014] The present invention will be further described in detail below with reference to the drawings.

[0015] As Figure 1-2A direct-drive eccentric forging unit shown in the figure comprises a housing 2 and a servo return system 8; the housing 2 is a high-strength cast steel integrated structure, and a torque motor mounting seat and an eccentric shaft support bearing are arranged inside the housing 2; a torque motor 1 is fixed on the mounting seat of the housing 2, and the output end of the torque motor 1 is connected to the eccentric shaft 5 by a keyless connection through a conical locking structure design of a clamping sleeve 4, so as to directly drive the eccentric shaft 5 to rotate; a flywheel 3 is installed at the driving end of the eccentric shaft 5, and the flywheel 3 is made of a nickel-based alloy, and its moment of inertia is adjusted by adding or removing a counterweight block. The eccentric distance of the eccentric shaft 5 is 5-50mm, its surface is nitrided, and it is connected to the slide 6 through a needle bearing; the slide 6 is arranged on the linear guide rail inside the box body 2, with a stroke accuracy of ±0.01mm, and the front end is connected to the connecting rod 7 through a ball hinge; shock-absorbing gaskets are provided at both ends of the connecting rod 7, one end of which is connected to the slide 6, and the other end drives the forging die 9; the servo return system 8 integrates a high-precision servo valve and a servo cylinder, which monitors the position of the slide 6 in real time and realizes dynamic reset through closed-loop control, and the reset response time is ≤10ms.

[0016] The forging die 9 is modular in design, and a nickel-based alloy layer is welded on the surface to improve wear resistance.

[0017] The servo return system 8 feeds back the displacement of the ram 6 in real time through the position sensor, and controls the reset speed of the ram 6 in conjunction with the servo cylinder.

[0018] The working process of the present invention is: The torque motor 1 of the present invention is fixed on the box body 2, and the torque motor 1 is started. The torque motor 1 drives the eccentric shaft 5 to rotate through the expansion sleeve 4, and the eccentric shaft 5 drives the slide 6 to reciprocate. The slide 6 drives the forging die 9 through the connecting rod 7 to complete the forging; the servo return system 8 monitors the slide position in real time and realizes dynamic reset through closed-loop control.

[0019] Example 1: Automobile half-axle forging Parameter configuration: Torque motor power: 40kW, speed range 0-1500r / min; Eccentricity: 3.5mm, forging force 1.4MN, frequency 1200 times / minute.

[0020] Workflow: Start the torque motor 3 to drive the eccentric shaft 6 to rotate, and the ram 7 reciprocates with a stroke of 3.5 mm; The flywheel 4 absorbs energy in the non-forging stroke and releases energy in the forging stroke, thus stably outputting the forging force; The servo return system 10 detects the ram position in real time and resets within 5ms after forging is completed to ensure continuous operation.

[0021] Effect verification: The dimensional deviation of the forging is ≤0.03 mm, and the surface roughness Ra is ≤1.6 μm; The unit energy consumption is reduced by 45% compared with the hydraulic drive equipment.

[0022] The above are only the preferred examples of the present invention. It should be pointed out that for those of ordinary skill in the art, under the technical inspiration provided by the present invention, as common general knowledge in the mechanical field, other equivalent variations and improvements can also be made, which should also be regarded as the protection scope of the present invention.

Claims

1. A direct-drive eccentric forging unit, characterized in that: It includes a box (2) and a servo return system (8); The housing (2) is a high-strength cast steel integrated structure, and is provided with a torque motor mounting seat and an eccentric shaft support bearing inside the housing (2); a torque motor (1) is fixed on the mounting seat of the housing (2), and the output end of the torque motor (1) is keylessly connected to the eccentric shaft (5) via a locking sleeve (4), so as to directly drive the eccentric shaft (5) to rotate; a flywheel (3) is installed at the driving end of the eccentric shaft (5), and the flywheel (3) is made of a nickel-based alloy, and its moment of inertia is adjusted by adding or removing a counterweight; the eccentric distance of the eccentric shaft (5) is 5-50 mm, and its surface is nitrided and connected to the slide ram (6) via a needle bearing; The ram (6) is arranged on a linear guide rail inside the box (2) and has a stroke accuracy of ±0.01 mm. The front end is connected to the connecting rod (7) via a ball hinge. Shock-absorbing washers are provided at both ends of the connecting rod (7), one end of which is connected to the ram (6) and the other end drives the forging die (9). The servo return system (8) integrates a high-precision servo valve and a servo oil cylinder, monitors the position of the ram (6) in real time and realizes dynamic reset through closed-loop control, with a reset response time of ≤10ms.

2. A direct-drive eccentric forging unit according to claim 1, characterized in that: The expansion sleeve (4) adopts a conical locking structure to achieve a keyless connection between the flywheel (3) and the eccentric shaft (5).

3. A direct-drive eccentric forging unit according to claim 2, characterized in that: The forging die (9) is of modular design, and has a nickel-based alloy layer built-up on its surface to improve wear resistance.

4. A direct-drive eccentric forging unit according to claim 3, characterized in that: The servo return system (8) provides real-time feedback of the displacement of the ram (6) via a position sensor, and works in conjunction with the servo oil cylinder to control the reset speed of the ram (6).

Images