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

Abstract

The present invention proposes an energy-saving device and method for a forging press, the device comprising a control module, a servo motor, a slider, and an energy storage module; the control module is connected to a servo driver via a control line, the servo driver is electrically connected to a 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 instructions to the servo driver to control the start and stop of the servo motor, and to drive the slider of the forging press to slide down by the servo motor to perform forging and striking to complete the forming of the workpiece; when the slider reaches the preset position of the bottom dead center through the encoder, the servo motor is controlled to drive the slider to rise to the top dead center position, and the energy storage module is used to store the electricity generated when the slider rises. Based on the energy-saving device for a forging press, an energy-saving method for a forging press is also proposed. The present invention can realize the braking of the forging press and the recovery of return energy, which can greatly reduce the power consumption and save energy and protect the environment.

Description

Technical Field

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

[0002] Forging presses are widely used in the fields of aviation, automobiles, and refractory forming due to their features such as short transmission chains and high precision. The operating process of a traditional forging press is as follows: after power is turned on, the ordinary motor is in a constant rotation state, and the motor drives the flywheel to rotate continuously. After clicking the start button, the clutch is engaged, and the flywheel drives the crankshaft to rotate, and the crankshaft then converts the rotational torque into kinetic energy of the slider to achieve forging of the workpiece. In this mode, the motor is always in a constant rotation state, and the reactive loss is extremely large. Secondly, at the moment of completion of a single forging and during the entire return stroke of the slider, due to the huge rotational 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 consumed 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 striking frequency of the press. Its striking speed and striking force cannot be adjusted, and striking control is achieved through clutch control. In the non-striking state, its motor still idles without any reactive power, and energy waste is extremely serious; in the striking state, the flywheel and slider transmit striking energy through the motor, but there is no recovery system for the slider return energy, and it can only be consumed through resistance or mechanical loss, which also causes great waste. In the striking process of traditional forging presses, energy input and output are mainly achieved through open-loop control, relying on preset parameters to adjust the flywheel speed and striking force. However, due to factors such as fluctuations in material deformation resistance, mechanical transmission loss and temperature rise, it is difficult for the open-loop system to adjust energy output in real time, resulting in energy waste (approximately 20% to 30% of total energy consumption) and reduced striking 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 energy-saving method for a forging press, which can realize braking of the forging press and return energy recovery, greatly reduce electricity consumption, and save energy and protect the environment.

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

[0006] A forging press energy-saving device includes: a control module, a servo motor 1, a slide 2 and an energy storage module 6;

[0007] The control module is connected to the servo driver via a control line, and the servo driver is electrically connected to the servo motor 1; the servo motor 1 is mechanically connected to the slide 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, and drive the slider 2 of the forging press to slide down through the servo motor 1 to perform forging and striking to complete the workpiece forming; when the slider 2 reaches the preset position of the bottom dead point through the encoder, the servo motor 1 is controlled to drive the slider 2 to return to the top dead point position, and the energy storage module 6 is used to store the electricity generated when the slider rises.

[0009] Furthermore, the energy storage module 6 is also used to release the stored electricity when the forging press is performing 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 is started, the crankshaft module is driven by the servo motor 1 to realize forward and reverse rotation.

[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 also includes a safety brake 5;

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

[0015] Furthermore, the device further comprises a material ejecting mechanism 6;

[0016] The ejection mechanism 6 is used to automatically eject the forged workpiece formed in the die after the forged workpiece is formed.

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

[0018] The present invention also proposes a forging press energy-saving method, which is implemented 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] The servo motor drives the slide of the forging press to slide down to forge and strike to complete the workpiece forming;

[0021] When the slider reaches the preset position of the bottom dead center through the encoder, the servo motor is controlled to drive the slider back to the top dead center position;

[0022] The energy storage module stores the electricity generated when the slider rises.

[0023] Furthermore, in the method: during the downward phase 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 forming material, the first speed is increased to prepare for rapid forging and forming.

[0024] Furthermore, in the method: when the slider contacts the molding material position, the servo motor drives the slider to apply pressure to quickly mold the material; after the striking is completed, pressure and heat are applied to the workpiece to ensure the molding quality of the workpiece.

[0025] Furthermore, 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 and generates more electricity.

[0026] The effects provided in the summary of the invention are only the effects of the embodiments, not all the effects of the invention. One of the above technical solutions has the following advantages or beneficial effects:

[0027] The present invention proposes an energy-saving device and 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 a servo driver via a control line, and the servo driver is electrically connected to a 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 instructions to the servo driver to control the start and stop of the servo motor, and the servo motor drives the slider of the forging press to slide downward to forge and strike the workpiece to complete the forming process. When the slider reaches a preset position at the bottom dead center via an encoder, the servo motor is controlled to drive the slider back to the top dead center position, and the energy storage module is used to store the electricity generated by the slider's rise. Based on the energy-saving device for a forging press, an energy-saving method for a forging press is also proposed. The present invention replaces the constant speed motor with an asynchronous servo motor through servo transmission control technology, adds a servo controller, replaces the flywheel and clutch system, and 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, so as to achieve the energy output size adjustment of the slider at different strokes. Through the three-in-one control architecture of sensor 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-strike state, and the electric motor can be converted into a generator in the brake return state to realize the conversion of braking energy from mechanical energy to electrical energy and store it in the capacitor cabinet. When the press strikes again, the electrical energy can be released to achieve secondary utilization of energy.

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

[0029] Figure 1This is a schematic diagram of an energy-saving device for a forging press proposed in Example 1 of the present invention;

[0030] Figure 2 This is a flow chart of a forging press energy-saving method proposed in Example 2 of the present invention;

[0031] Figure 3 This is a forging interpolation curve diagram proposed in Example 2 of the present invention;

[0032] Figure 4 This is a flow chart of energy and signal conversion during the execution of a forging press energy-saving method proposed in Example 2 of the present invention;

[0033] Legend: 1-Servo motor; 2-Slider; 3-Lubrication mechanism; 4-Frame; 5-Safety brake; 6. Energy storage module; 7-Ejection mechanism. DETAILED DESCRIPTION

[0034] In order to clearly illustrate the technical features of this solution, the present invention is described in detail below through specific implementation methods and in conjunction with the accompanying drawings. The disclosure below provides many different embodiments or examples for realizing different structures of the present invention. In order 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 numbers and / or letters in different examples. This repetition is for the purpose of simplicity 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 accompanying drawings are not necessarily drawn to scale. The present invention omits descriptions of well-known components and processing technologies and processes to avoid unnecessary limitations on the present invention.

[0035] Example 1

[0036] The energy-saving device for a forging press proposed in Example 1 of the present invention is used to solve the technical problems existing in the striking process of a traditional forging press.

[0037] The present invention replaces the constant speed motor with an asynchronous servo motor through servo transmission control technology and adds a servo controller. The flywheel and clutch system are replaced, and 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, so as to adjust the energy output of the slider at different strokes. Through the three-in-one control architecture of sensor perception-controller decision-making-servo motor execution, the closed-loop control of the entire operating system is completed; the motor can be stopped in the non-strike state, and the electric motor can be converted into a generator in the brake return state to convert the braking energy from mechanical energy to electrical energy and store it in the capacitor cabinet. When the press strikes again, the electrical energy can be released, realizing the secondary utilization of energy.

[0038] Figure 1This is a schematic diagram of an energy-saving device for a forging press proposed in Example 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 via 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 instructions to the servo driver to control the start and stop of the servo motor 1, and drive the slider 2 of the forging press to slide down through the servo motor 1 to perform forging and striking to complete the workpiece forming; when the slider 2 reaches the preset position of the bottom dead point through the encoder, the servo motor 1 is controlled to drive the slider 2 to return to the top dead point position, and the energy storage module 6 is used to store the electricity generated when the slider rises.

[0041] The energy storage module 6 is also used to release the stored electricity when the forging press is performing a secondary forging strike, thereby realizing secondary utilization of energy.

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

[0043] The servo motor 1 provides the power source for the entire press, driving the other components. The flywheel stores the servo motor's energy and releases it during the forging process to provide sufficient energy. The pulley and gears transmit the servo motor's power, transferring the rotational motion to the crankshaft module, achieving motion conversion and transmission.

[0044] In this application, the servo motor 1 is connected to the crankshaft module of the forging press. 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. As the crankshaft rotates, the slider 1 begins to move downward. The slider 2 directly contacts the mold, transmits the motion to the mold, and forges the workpiece. The crank converts the rotational motion transmitted by the servo motor 1 into the reciprocating motion of the connecting rod. The connecting rod is used to connect the crank and the slider 1, converting the rotational motion of the crank into the up and down reciprocating motion of the slider 1.

[0045] The device further comprises 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.

[0046] The device further comprises an 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.

[0047] In the present application, the servo motor 1 , the slide 2 , the lubrication mechanism 4 , the safety brake 5 , the energy storage system 6 and the ejection 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 braking of the forging press and return energy recovery, thereby significantly reducing power consumption and being energy-saving and environmentally friendly.

[0049] Example 2

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

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

[0052] The servo motor drives the slide of the forging press to slide down to forge and strike to complete the workpiece forming;

[0053] When the slider reaches the preset position of the bottom dead center through the encoder, the servo motor is controlled to drive the slider back to the top dead center position;

[0054] The energy storage module stores the electricity generated when the slider rises.

[0055] The description of the relevant parts of the forging press energy-saving method provided in Example 2 of the present application can be found in the detailed description of the corresponding parts of the forging press energy-saving device provided in Example 1 of the present application, and will not be repeated here.

[0056] Figure 2 This is a flow chart of a forging press energy-saving method proposed in Example 2 of the present invention;

[0057] In step S200, enable preparation, connect the three-phase main power supply, close the electrical branch circuit breakers, press the "operation preparation" button, and the corresponding indicator light will light up.

[0058] In step S201, press the "Motor Start" button to control the pump motor to start, and then the mold pad main motor starts (star-delta). After completion, the corresponding indicator light is on; the servo motor is enabled and ready to run, and the corresponding indicator light is on.

[0059] In step S202, the crankshaft is driven. Because the present invention eliminates the flywheel and clutch system, the servo motor is directly connected to the crankshaft system. After the motor is started, the crankshaft system is driven by the motor to achieve forward and reverse rotation.

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

[0061] In step S204, braking begins when the slider approaches the bottom dead center (2 mm from the bottom dead center); when braking begins, the conversion from the motor to the generator is realized under the action of rebound force and inertia. At this time, the computer is transmitted to the storage capacitor through the AC-DC control strategy and energy management strategy to realize electrical energy recovery and utilization, and 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 , the crankshaft drive is reversed.

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

[0065] This application uses an interpolation curve control strategy, and the motor can provide different speeds at different stages according to the requirements of the forging process. Figure 3 This is a forging interpolation curve diagram proposed in Example 2 of the present invention;

[0066] ① During the downward starting phase of the slider, the servo motor can use the slider's own weight to descend at a high speed, reducing energy consumption;

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

[0068] ③ When the slider contacts the molding material, the servo motor drives the slider to rapidly pressurize. At this time, the speed reaches 100%, and the material is quickly molded, reducing the impact time while ensuring the molding quality;

[0069] ④ After the striking 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 is optimal. Therefore, the slider is in a slow pressurization state until it reaches 2mm from the bottom dead center;

[0070] ⑤ After the pressure is maintained, the servo motor drives the slide to rapidly return to top dead center at 100% speed, increasing the number of times the rotor cuts through the magnetic flux lines, generating more electricity. This multi-stage variable speed control strategy not only improves energy efficiency but also enhances forging precision. This control strategy enables the forging press to flexibly adjust the motor speed according to different process requirements, improving the system's adaptability and flexibility. Especially during the slide's descent phase, the high motor speed ensures rapid descent, improving production efficiency.

[0071] Figure 4This is a flow chart of energy and signal conversion during the execution of a forging press energy-saving method proposed in Example 2 of the present invention; Braking energy recovery is the core technology for servo-driven forging presses to achieve energy saving and efficiency improvement. Its core goal is to significantly reduce the energy consumption of equipment operation by converting the kinetic energy of the flywheel braking stage into electrical energy and feeding it back to the power grid or energy storage system. After the forging press completes the forging blow, the flywheel and transmission system still have a large amount of kinetic energy due to inertia. Traditional equipment converts this part of energy into heat energy through mechanical braking or resistance energy consumption, resulting in energy waste (accounting for approximately 25% to 40% of the total energy consumption of a single cycle). Braking energy recovery technology converts mechanical energy into electrical energy and feeds it back to the power grid or storage device by switching the motor to a power generation state, thereby achieving energy reuse. The energy recovery mechanism not only reduces dependence on external power supplies, but also improves the overall efficiency of the system. Especially in the slider rising stage, energy recovery and storage provide additional energy support for the subsequent forging process, further reducing energy consumption.

[0072] The braking energy conversion mechanism is as follows: During the forging press's operating cycle, the slide must brake quickly after striking the forging to prepare for the next movement. After servo-based modification, the asynchronous induction motor switches from "motor mode" to "generator mode" during the braking phase. Braking energy is converted from AC to DC by the controller and stored in the capacitor system. The energy conversion process is as follows:

[0073]

[0074] Among them, E regen is the converted energy; ω1 is the initial angular velocity of braking, ω2 is the angular velocity of braking end, η inv is the inverter efficiency (≥95%), η grid is the grid-connected efficiency (≥90%); J is the braking energy.

[0075] The present invention adopts a capacitor energy storage buffer method, which temporarily stores the flywheel slider return and braking energy through a capacitor bank in series, and releases the energy again when the slider strikes the component, thereby achieving energy saving. The energy storage system capacity design formula is:

[0076]

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

[0078] The energy recovery system, through closed-loop management, monitors system status in real time and dynamically adjusts driving and braking strategies, ensuring precise control and efficient energy utilization, thereby achieving energy conservation. Compared to traditional braking methods that rely on mechanical friction or resistance, the servo-based solution, through motor generation and intelligent control strategies, can increase energy recovery efficiency from less than 5% to over 30%.

[0079] Embodiment 2 of the present invention proposes an energy-saving method for a forging press, which can realize braking of the forging press and return energy recovery, thereby significantly reducing power consumption and being energy-saving and environmentally friendly.

[0080] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply the existence of any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that the process, method, article or device comprising a series of elements are inherent to the elements. In the absence of further restrictions, the elements limited by the statement "comprise one..." do not exclude the presence of other identical elements in the process, method, article or device comprising the elements. In addition, the above-mentioned technical solutions provided in the embodiments of the present application are not described in detail in accordance with the corresponding technical solutions in the prior art to achieve the same principle, so as to avoid excessive elaboration.

[0081] Although the above description is of specific embodiments of the present invention in conjunction with the accompanying drawings, it does not limit the scope of protection of the present invention. For those skilled in the art, other different forms of modifications or variations can be made based on the above description. It is not necessary and impossible to list all embodiments here. Based on the technical solution of the present invention, various modifications or variations that can be made by those skilled in the art without expending creative effort are still within the scope of protection of the present invention.

Claims

1. A forging press energy-saving method, characterized in that: An energy-saving device is included, wherein the energy-saving device includes: a control module, a servo motor (1), a slider (2) and an energy storage module (6); The control module is connected to the servo driver via 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); 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 the crankshaft module of the forging press, and after the servo motor (1) is started, the crankshaft module realizes forward and reverse rotation under the drive of the servo motor (1); the crankshaft module is directly connected to the slider (2), and as the crankshaft rotates, the slider (2) starts to move downward; 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 workpiece forming; when the slider (2) reaches a preset position of the bottom dead point through the encoder, the servo motor (1) is controlled to drive the slider (2) to rise to the top dead point position, and the energy storage module (6) is used to store the electricity generated when the slider (2) rises; Sending control instructions to the servo driver through the control module to control the start and stop of the servo motor (1); The servo motor (1) drives the slider (2) of the forging press to descend to forge and strike the workpiece to complete the forming of the workpiece; in the descending stage of the slider (2), the servo motor (1) uses the slider (2)'s own weight to descend at a first speed, and when the slider (2) is at a preset position away from the forming material, the first speed is increased by 10% to prepare for rapid forging and forming; When the slider (2) reaches the preset position of the bottom dead center through the encoder, the servo motor (1) is controlled to drive the slider (2) to rise to the top dead center position; when the slider (2) contacts the molding material position, the servo motor (1) drives the slider (2) to pressurize so that the material is quickly molded; after the impact is completed, pressure and heat are applied to the workpiece to ensure the molding quality of the workpiece. At this time, the slider (2) is in a slow pressurization state until it reaches 2 mm from the bottom dead center; The energy storage module (6) stores the electricity generated when the slider (2) rises; After the pressure maintenance is completed, the servo motor (1) drives the slider (2) to return to the top dead center position at the second speed, so as to increase the number of times the rotor cuts the magnetic lines of force and generate more electricity.

2. The forging press energy-saving method according to claim 1, characterized in that: The energy storage module (6) is also used to release the stored electricity when the forging press performs a secondary forging strike.

3. The forging press energy-saving method 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.

4. The method for energy saving of a forging press according to claim 1, characterized in that: The device also includes a material ejection mechanism (7); The ejection mechanism (7) is used to automatically eject the forged workpiece formed in the die after the forged workpiece is formed.

5. A forging press energy-saving method according to any one of claims 1 to 4, characterized in that: The control module adopts a PLC control module; the energy storage module (6) adopts a series capacitor.

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