Energy-saving device and energy-saving method for forging press

Abstract

The invention provides an energy-saving device and method for a forging press. The energy-saving device comprises a control module, a servo motor, a sliding block and an energy storage module. The control module is connected with the servo driver through a control line, and the servo driver is electrically connected with the servo motor; the servo motor is mechanically connected with a sliding block of the forging press; the control module is in communication connection with the energy storage module; the control module is used for sending a control instruction to the servo driver and controlling starting and stopping of the servo motor, and the servo motor drives a sliding block of the forging press to slide downwards for forging and striking to complete workpiece forming. When the encoder obtains that the sliding block reaches the preset position of the bottom dead center, the servo motor is controlled to drive the sliding block to rise to the position of the top dead center, and the energy storage module stores the electric quantity generated when the sliding block rises. Based on the energy-saving device of the forging press, the invention further provides an energy-saving method of the forging press. Braking and return stroke energy recovery of the forging press can be achieved, electric energy consumption can be greatly reduced, and energy conservation and environmental protection are achieved.

Description

Technical Field

[0001] The present invention belongs to the technical field of forging presses, and particularly relates to an energy-saving device and an energy-saving method for forging presses. Background Art

[0002] Forging presses are widely used in the fields of aviation, automotive, and refractory material forming due to characteristics such as short transmission chains and high precision. The operation process of traditional forging presses is as follows: After power-on, the ordinary motor rotates constantly, and the motor drives the flywheel to rotate continuously. After clicking the start button, the clutch engages, the flywheel drives the crankshaft to rotate, and the crankshaft then converts the rotational torque into the up-and-down kinetic energy of the slider to achieve forging of the workpiece. In this mode, the motor is always in a constant rotation state, resulting in extremely large reactive power losses. Secondly, at the moment when a single forging is completed and during the entire return process of the slider, due to the huge moment of inertia of the slider and the weight of the slider itself, the kinetic energy generated is extremely large, and this kinetic energy can only be dissipated through mechanical braking or resistance in the traditional mode, resulting in huge energy waste.

[0003] Therefore, traditional forging presses use fixed-speed motors to achieve a constant stamping frequency of the press, and their stamping speed and stamping force cannot be adjusted. The stamping control is achieved through clutch control. When in a non-stamping state, the motor still idles without work, resulting in extremely serious energy waste; in the stamping state, the flywheel and the slider apply stamping energy through motor conduction, but there is no energy recovery system for the return energy of the slider, and it can only be dissipated through resistance or mechanical loss, also causing great waste. During the stamping process of traditional forging presses, the energy input and output are mainly achieved through open-loop control, relying on preset parameters to adjust the flywheel speed and stamping force. However, due to factors such as fluctuations in the deformation resistance of materials, mechanical transmission losses, and temperature rise, the open-loop system is difficult to adjust the energy output in real time, resulting in energy consumption waste (accounting for about 20% - 30% of the total energy consumption) and a decrease in stamping accuracy (error ≥ 5%). Summary of the Invention

[0004] In order to solve the above technical problems, the present invention proposes an energy-saving device and an energy-saving method for forging presses, which can achieve the recovery of braking and return energy of forging presses, greatly reduce power consumption, and save energy and protect the environment.

[0005] To achieve the above object, the present invention adopts the following technical solutions:

[0006] An energy-saving device for a forging press, comprising: a control module, a servo motor 1, a slider 2, and an energy storage module 6;

[0007] The control module is connected to a servo driver through a control line, and the servo driver is electrically connected to the servo motor 1; the servo motor 1 is mechanically connected to the slider 2 of the forging press; the control module is communicatively connected to the energy storage module 6;

[0008] The control module is used to send control instructions to the servo driver to control the start and stop of the servo motor 1. The servo motor 1 drives the slider 2 of the forging press to slide down for forging strikes to complete the workpiece forming. When the encoder obtains that the slider 2 reaches the preset position at the bottom dead center, the control module controls the servo motor 1 to drive the slider 2 to rise back to the top dead center position, and the power generated when the slider rises is stored through the energy storage module 6.

[0009] Furthermore, the energy storage module 6 is also used to release the stored power when the forging press performs secondary forging strikes.

[0010] Furthermore, the mechanical connection between the servo motor 1 and the slider 2 of the forging press specifically includes:

[0011] The servo motor 1 is connected to the crankshaft module of the forging press. After the servo motor 1 starts, the crankshaft module rotates forward and backward under the drive of the servo motor 1.

[0012] The crankshaft module is directly connected to the slider 2. As the crankshaft rotates, the slider 1 starts to move downward.

[0013] Furthermore, the device further includes a safety brake 5;

[0014] The safety brake 5 is used to apply a braking force when the servo motor 1 stops operating, and prevent the rotation of the servo motor 1 through friction or electromagnetic action.

[0015] Furthermore, the device further includes a knockout mechanism 6;

[0016] The knockout mechanism 6 is used to automatically eject the forged workpiece formed in the mold after the forging workpiece is formed.

[0017] Furthermore, the control module adopts a PLC control module; the energy storage module 6 adopts series capacitors.

[0018] The present invention also proposes a forging press energy-saving method, which is realized based on a forging press energy-saving device, and includes the following steps:

[0019] Send control instructions to the servo driver through the control module to control the start and stop of the servo motor;

[0020] Drive the slider of the forging press to slide down through the servo motor for forging strikes to complete the workpiece forming;

[0021] When the encoder obtains that the slider reaches the preset position at the bottom dead center, control the servo motor to drive the slider to rise back to the top dead center position;

[0022] Store the power generated when the slider rises through the energy storage module.

[0023] Further, in the method: during the downward movement of the slider, the servo motor descends at a first speed by utilizing the self-weight of the slider. When the slider is at a preset position from the forming material, the first speed is increased to prepare for rapid forging and forming.

[0024] Further, in the method: when the slider contacts the forming material position, the servo motor drives the slider to apply pressure to rapidly form the material; after the forging is completed, pressure and heating are applied to the workpiece to ensure the forming quality of the workpiece.

[0025] Further, in the method, after the pressure holding is completed, the servo motor drives the slider to rise to the top dead center position at a second speed to increase the number of times the rotor cuts the magnetic field lines and generate more electricity.

[0026] The effects provided in the invention content are only the effects of the embodiments, rather than all the effects of the invention. One of the above technical solutions has the following advantages or beneficial effects:

[0027] The present invention provides an energy-saving device and an energy-saving method for a forging press. The device includes a control module, a servo motor, a slider, and an energy storage module; the control module is connected to the servo driver through a control line, and the servo driver is electrically connected to the servo motor; the servo motor is mechanically connected to the slider of the forging press; the control module is communicatively connected to the energy storage module; the control module is used to send control commands to the servo driver to control the start and stop of the servo motor, drive the slider of the forging press to slide down through the servo motor to complete the forging and forming of the workpiece; when the slider reaches a preset position at the bottom dead center through the encoder, control the servo motor to drive the slider to rise to the top dead center position, and store the electricity generated when the slider rises through the energy storage module. Based on an energy-saving device for a forging press, an energy-saving method for a forging press is also provided. The present invention replaces the constant-speed motor with an asynchronous servo motor through servo drive control technology, adds a servo controller, replaces the flywheel and clutch system, the asynchronous servo motor is directly connected to the crankshaft through a coupling, the servo controller controls the motor to achieve rapid start and stop, and is designed with an encoder to feedback the motor speed and stroke position to realize the adjustment of the energy output size of the slider at different strokes. Through the trinity control architecture of sensing perception - controller decision - servo motor execution, the closed-loop control of the entire operating system is completed. The motor can be stopped in the non-striking state, and the motor can be converted into a generator in the braking return state to convert the braking energy from mechanical energy into electrical energy and store it in the capacitor cabinet. When the press strikes again, the electrical energy can be released to realize the secondary utilization of energy.

[0028] The present invention can realize the recovery of the braking and return energy of the forging press, can greatly reduce the power consumption, and is energy-saving and environment-friendly. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1Schematic diagram of an energy-saving device for a forging press proposed in Embodiment 1 of the present invention;

[0030] Figure 2 Flowchart of an energy-saving method for a forging press proposed in Embodiment 2 of the present invention;

[0031] Figure 3 Forging interpolation curve graph proposed in Embodiment 2 of the present invention;

[0032] Figure 4 Flowchart of energy and signal conversion during the execution of an energy-saving method for a forging press proposed in Embodiment 2 of the present invention;

[0033] Legend: 1 - Servo motor; 2 - Slide block; 3 - Lubrication mechanism; 4 - Frame; 5 - Safety brake; 6 - Energy storage module; 7 - Ejector mechanism. Detailed implementation manners

[0034] To clearly illustrate the technical features of this solution, the present invention will be elaborated in detail below through specific implementation manners and in conjunction with its accompanying drawings. The following disclosure provides many different embodiments or examples for implementing different structures of the present invention. To simplify the disclosure of the present invention, the components and settings of specific examples are described below. In addition, the present invention may repeat reference numerals and / or letters in different examples. This repetition is for the purpose of simplification and clarity, and does not itself indicate the relationship between the various embodiments and / or settings discussed. It should be noted that the components illustrated in the drawings are not necessarily drawn to scale. The present invention omits the description of well-known components and processing technologies and processes to avoid unnecessarily limiting the present invention.

[0035] Embodiment 1

[0036] An energy-saving device for a forging press proposed in Embodiment 1 of the present invention is used to solve the technical problems existing in traditional forging presses during the stamping process.

[0037] In the present invention, the constant-speed motor is replaced with an asynchronous servo motor through servo drive control technology, and a servo controller is added. The flywheel and clutch system are replaced. The asynchronous servo motor is directly connected to the crankshaft through a coupling. The servo controller controls the motor to achieve fast start and stop, and an encoder is designed to feedback the motor speed and stroke position to realize the adjustment of the energy output size of the slide block at different strokes. Through the trinity control architecture of sensing perception - controller decision - servo motor execution, the closed-loop control of the entire operating system is completed; the motor can be stopped in the non-stamping state, and the motor can be converted into a generator in the braking return state to convert the braking energy from mechanical energy into electrical energy and store it in the capacitor cabinet. When the press stamps again, the electrical energy can be released to realize the secondary utilization of energy.

[0038] Figure 1Schematic diagram of an energy-saving device for a forging press proposed in Embodiment 1 of the present invention; the device includes: a control module, a servo motor 1, a slider 2, and an energy storage module 6;

[0039] The control module is connected to the servo driver through a control line, and the servo driver is electrically connected to the servo motor 1; the servo motor 1 is mechanically connected to the slider 2 of the forging press; the control module is communicatively connected to the energy storage module 6;

[0040] The control module is used to send control commands to the servo driver, control the start and stop of the servo motor 1, drive the slider 2 of the forging press to slide down through the servo motor 1 to complete forging strikes and form workpieces; when the slider 2 reaches a preset position at the bottom dead center through an encoder, control the servo motor 1 to drive the slider 2 to rise to the top dead center position, and store the electric energy generated when the slider rises through the energy storage module 6.

[0041] The energy storage module 6 is also used to release the stored electric energy during the second forging strike of the forging press to achieve secondary utilization of energy.

[0042] In this application, the control module uses a PLC module; the energy storage module 6 uses series capacitors.

[0043] The servo motor 1 provides a power source for the entire press and drives the operation of other components; the flywheel is used to store the energy of the servo motor 1 and release it during the forging process to provide sufficient energy. The pulley and gear are used to transmit the power of the servo motor 1 and transfer the rotational motion to the crankshaft module to achieve the conversion and transmission of motion.

[0044] In this application, the servo motor 1 is connected to the crankshaft module of the forging press. After the servo motor 1 starts, the crankshaft module rotates forward and backward under the drive of the servo motor 1; the crankshaft module is directly connected to the slider 2. As the crankshaft rotates, the slider 1 starts to move downward. The slider 2 is directly in contact with the mold and transfers the motion to the mold to forge the workpiece. The crank converts the rotational motion transmitted by the servo motor 1 into a reciprocating motion of the connecting rod. The connecting rod is used to connect the crank and the slider 1 and convert the rotational motion of the crank into an up-and-down reciprocating motion of the slider 1.

[0045] The device also includes a safety brake 5; the safety brake 5 is used to apply a braking force when the servo motor 1 stops rotating to prevent the rotation of the servo motor 1 through friction or electromagnetic action.

[0046] The device also includes a knockout mechanism 6; the knockout mechanism 6 is used to automatically eject the forged workpiece formed in the mold after the forging of the workpiece is completed.

[0047] In this application, the servo motor 1, the slider 2, the lubrication mechanism 4, the safety brake 5, the energy storage system 6, and the knockout mechanism 7 are all located on the frame 4 of the servo forging press.

[0048] Embodiment 1 of the present invention proposes an energy-saving device for a forging press, which can realize the braking of the forging press and the energy recovery during the return stroke, greatly reduce the power consumption, and save energy and protect the environment.

[0049] Embodiment 2

[0050] Based on the energy-saving device for a forging press proposed in Embodiment 1 of the present invention, Embodiment 2 of the present invention also proposes an energy-saving method for a forging press. This energy-saving method is the working process of the energy-saving device for a forging press proposed in Embodiment 1 of the present invention, specifically as follows:

[0051] Send a control command to the servo driver through the control module to control the start and stop of the servo motor;

[0052] Drive the slider of the forging press to slide down through the servo motor to perform forging strikes to complete the forming of the workpiece;

[0053] When the slider reaches the preset position at the bottom dead center through the encoder, control the servo motor to drive the slider to rise to the top dead center position;

[0054] Store the electric energy generated when the slider rises through the energy storage module.

[0055] For the description of the relevant parts in the energy-saving method for a forging press provided in Embodiment 2 of the present application, reference can be made to the detailed description of the corresponding parts in the energy-saving device for a forging press provided in Embodiment 1 of the present application, which will not be elaborated here.

[0056] Figure 2 It is a flowchart of an energy-saving method for a forging press proposed in Embodiment 2 of the present invention;

[0057] In step S200, enable preparation, turn on the three-phase main power supply, close the circuit breakers of each electrical branch, and press the "Operation Preparation" button, and the corresponding indicator light will be on.

[0058] In step S201, press the "Motor Start" button to control the start of the pump motor, and then start the die cushion main motor (star-delta). After completion, the corresponding indicator light will be on; enable the servo motor and prepare to run, and the corresponding indicator light will be on.

[0059] In step S202, crankshaft transmission. Since the present invention cancels the flywheel and clutch system, the servo motor is directly connected to the crankshaft system. After the motor starts, the crankshaft system rotates forward and backward under the drive of the motor.

[0060] In step S203, the crankshaft system is directly connected to the slider. As the crankshaft rotates, the slider starts to move downward.

[0061] In step S204, braking starts when the slider approaches the bottom dead center (2 mm away from the bottom dead center); when braking starts, the conversion from the motor to the generator is achieved under the action of the rebound force and inertia. At this time, the computer is delivered to the storage capacitor through the AC-DC control strategy and the energy management strategy to realize the recycling of electric energy, and then return to step S200.

[0062] In step S205, when the slider reaches the bottom dead center, the slider starts to move back.

[0063] In step S206, reverse crankshaft transmission.

[0064] In step S207, one jogging process ends, the slider moves back, and returns to step S200.

[0065] Through the interpolation curve control strategy in this application, the motor can provide different rotational speeds at different stages according to the requirements of the forging process. Figure 3 It is the forging interpolation curve graph proposed in Embodiment 2 of the present invention;

[0066] ① In the starting stage of the slider moving downward, the servo motor can use the self-weight of the slider to rapidly descend at a relatively high rotational speed, reducing energy consumption;

[0067] ② When the slider approaches the position of the forming material, the servo motor quickly increases the rotational speed by 10% to prepare for rapid forging and forming;

[0068] ③ When the slider contacts the position of the forming material, the servo motor drives the slider to rapidly apply pressure. At this time, the speed reaches 100%, the material is rapidly formed, the impact time is reduced, and the forming quality is ensured at the same time;

[0069] ④ After the impact is completed, the workpiece is in a hot forming state. At this time, a certain pressure and temperature need to be applied to the workpiece to ensure that the forming quality of the workpiece reaches the best. Therefore, at this time, the slider is in a state of slow pressure application until it reaches 2 mm away from the bottom dead center;

[0070] ⑤ After the pressure holding is completed, the servo motor drives the slider to rapidly rise to the top dead center position at a speed of 100% to increase the number of times the rotor cuts the magnetic field lines and generate more electric energy. This multi-stage variable speed control strategy not only improves the energy utilization efficiency but also improves the forging accuracy. This control strategy enables the forging press to flexibly adjust the rotational speed of the motor according to different process requirements, improving the adaptability and flexibility of the system. Especially in the stage of the slider descending, the high rotational speed of the motor can ensure the rapid descent of the slider and improve the production efficiency.

[0071] Figure 4It is the flowchart of energy and signal conversion during the execution of an energy-saving method for a forging press proposed in Embodiment 2 of the present invention; braking energy recovery is the core technology for a servo forging press to achieve energy conservation and efficiency improvement. Its core goal is to convert the kinetic energy during the flywheel braking stage into electrical energy and feed it back to the power grid or energy storage system, significantly reducing the energy consumption during equipment operation. After the forging press completes the forging strike, the flywheel and transmission system still have a large amount of kinetic energy due to inertia. Traditional equipment dissipates this part of the energy as heat through mechanical braking or resistance energy consumption, resulting in energy waste (accounting for about 25% - 40% of the total energy consumption in a single cycle). The braking energy recovery technology realizes the reuse of energy by switching the motor to the power generation state and converting mechanical energy into electrical energy to be fed back to the power grid or storage device. The energy recovery mechanism can not only reduce the dependence on external power sources but also improve the overall efficiency of the system. Especially during the upward movement of the slider, the recovery and storage of energy provide additional energy support for the subsequent forging process, further reducing energy consumption.

[0072] Its braking energy conversion mechanism is as follows: In the working cycle of the forging press, after the slider completes the forging of the workpiece, it needs to be quickly braked to prepare for the next action. After the servo transformation, the asynchronous induction motor switches from the "electric mode" to the "power generation mode" during the braking stage, and the braking energy is stored in the capacitor system after AC-DC conversion by the controller. Its energy conversion process is as follows:

[0073]

[0074] Among them, E regen is the converted energy; ω 1 is the initial braking angular velocity, ω 2 is the ending braking angular velocity, η inv is the inverter efficiency (≥95%), η grid is the grid connection efficiency (≥90%); J is the braking energy.

[0075] In the present invention, a capacitor energy storage buffer method is adopted. The flywheel slider return and braking energy are temporarily stored through the series connection of capacitor banks, and the energy is released again during the process of the slider hitting the workpiece, so as to achieve the energy-saving effect. The design formula for the capacity of the energy storage system is:

[0076]

[0077] Among them, C cap is the total capacity of the energy storage system, V max and V min are the allowable voltage fluctuation ranges of the bus voltage respectively.

[0078] Through closed-loop management, the energy recovery system can monitor the system status in real time, dynamically adjust the driving and braking strategies, ensure the precise control and efficient utilization of energy, and thus achieve the energy-saving goal. Compared with the traditional braking method that uses mechanical friction or resistance energy consumption, the servo solution can increase the energy recovery efficiency from less than 5% to more than 30% through the motor power generation mode and intelligent control strategy.

[0079] The energy-saving method for a forging press proposed in Embodiment 2 of the present invention can achieve the energy recovery of the braking and return stroke of the forging press, greatly reduce the power consumption, and save energy and protect the environment.

[0080] It should be noted that in this article, relational terms such as first and second are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the term "including", "comprising" or any other variant thereof is intended to cover non-exclusive inclusion, so that the elements inherent in a process, method, article or device including a series of elements. Without further limitation, the element defined by the statement "including one..." does not exclude the existence of additional identical elements in the process, method, article or device including the said element. In addition, the parts of the above technical solutions provided in the embodiments of the present application that are consistent with the corresponding technical solutions in the prior art in terms of implementation principles are not described in detail to avoid excessive elaboration.

[0081] Although the specific implementation manners of the present invention have been described above in conjunction with the accompanying drawings, it is not a limitation on the protection scope of the present invention. For those skilled in the art, other different forms of modification or variation can be made on the basis of the above description. It is not necessary and impossible to list all the implementation manners here. Based on the technical solutions of the present invention, various modifications or variations that can be made by those skilled in the art without creative labor are still within the protection scope of the present invention.

Claims

1. A forging press energy-saving device, characterized in that: include: A control module, a servo motor (1), a slider (2) and an energy storage module (6); The control module is connected to a servo driver via a control line, and the servo driver is electrically connected to a servo motor (1); the servo motor (1) is mechanically connected to a slider (2) of a forging press; and the control module is communicatively connected to an energy storage module (6); The control module is used to send control instructions to the servo driver to control the start and stop of the servo motor (1), and to drive the slider (2) of the forging press to slide down through the servo motor (1) to perform forging and striking to complete the forming of the workpiece; when the slider (2) reaches a preset position of the lower dead point through the encoder, the servo motor (1) is controlled to drive the slider (2) to rise to the upper dead point position, and the energy storage module (6) is used to store the electricity generated when the slider rises.

2. A forging press energy saving device according to claim 1, characterized in that: The energy storage module (6) is also used to release the stored electricity when the forging press is performing secondary forging strikes.

3. The forging press energy saving device according to claim 1, characterized in that: The mechanical connection between the servo motor (1) and the slider (2) of the forging press specifically includes: The servo motor (1) is connected to a crankshaft module of a forging press, and after the servo motor (1) is started, the crankshaft module is driven by the servo motor (1) to realize forward and reverse rotation; The crankshaft module is directly connected to the slider (2), and as the crankshaft rotates, the slider (1) starts to move downward.

4. The forging press energy saving device according to claim 1, characterized in that: The device also includes a safety brake (5); The safety brake (5) is used to apply a braking force when the servo motor (1) stops running, thereby preventing the servo motor (1) from rotating through friction or electromagnetic action.

5. The forging press energy saving device according to claim 1, characterized in that: The device also includes a material ejection mechanism (6); The ejection mechanism (6) is used to automatically eject the forged workpiece formed in the die after the forged workpiece is formed.

6. A forging press energy saving device according to any one of claims 1 to 5, characterized in that: The control module adopts a PLC control module; the energy storage module (6) adopts a series capacitor.

7. A forging press energy-saving method is implemented based on a forging press energy-saving device, characterized in that: The following steps are involved: Send control instructions to the servo driver through the control module to control the start and stop of the servo motor; The servo motor drives the slide of the forging press to slide down to forge and strike the workpiece to form the workpiece; When the slider reaches the preset position of the bottom dead point through the encoder, the servo motor is controlled to drive the slider to rise to the top dead point position; The electricity generated when the slider rises is stored through the energy storage module.

8. A forging press energy saving method according to claim 7, characterized in that: In the method, during the downward movement of the slider, the servo motor uses the slider's own weight to descend at a first speed, and when the slider is at a preset position away from the molding material, the first speed is increased to prepare for rapid forging and molding.

9. A forging press energy saving method according to claim 7, characterized in that: In the method, when the slider contacts the molding material position, the servo motor drives the slider to pressurize the material so that the material is quickly molded; after the striking is completed, pressure and heat are applied to the workpiece to ensure the molding quality of the workpiece.

10. A forging press energy saving method according to claim 7, characterized in that: In the method, after the pressure maintenance is completed, the servo motor drives the slider to return to the top dead center position at a second speed to increase the number of times the rotor cuts the magnetic lines of force to generate more electricity.

Images