Pressure relief and unloading system of hydraulic machine

Abstract

The invention discloses a hydraulic machine pressure relief and unloading system, and relates to the technical field of hydraulic pressure relief and unloading systems, the hydraulic machine pressure relief and unloading system comprises a pressure relief and unloading system, the pressure relief and unloading system comprises a power unit, an execution unit, a control unit, a pressure relief and unloading unit and an auxiliary unit, and the output end of the power unit is fixedly connected with the input end of the execution unit; the execution unit is in bidirectional connection with the control unit, the output end of the auxiliary unit is fixedly connected with the input end of the power unit, the output end of the pressure relief and unloading unit is fixedly connected with the input end of the power unit and the input end of the auxiliary unit, and pressure relief is triggered 10-50 ms in advance through AI prediction in the intelligent prediction module. The ineffective pressure maintaining time is shortened, the energy consumption of a main motor is reduced by 12%-18%, the pressure peak fluctuation range is reduced by 40% by dynamically adjusting the pressure relief threshold value, and the service life of a pipeline and the service life of a sealing piece are prolonged by 30% or above.

Description

Technical Field

[0001] The present invention relates to the technical field of hydraulic pressure relief and unloading systems, in particular to a hydraulic press pressure relief and unloading system. Background Art

[0002] The hydraulic press pressure relief and unloading system is an important part of the hydraulic press to ensure equipment safety, improve efficiency and extend life. Its core function is to control the hydraulic press at a specific stage of the working cycle.

[0003] According to the patent titled "Intelligent Hydraulic Control System for Bidirectional Pressing Hydraulic Press" (Patent Publication No.: CN101164766A, Patent Publication Date: April 23, 2008), the system includes an upper master cylinder, a lower master cylinder, a valve group, an oil circuit, an oil pump, and an oil tank. The valve group includes upper and lower master cylinder proportional pump groups, upper and lower master cylinder pump outlet valve groups, a support valve group, upper and lower master cylinder control valve groups, a conversion valve group, upper and lower master cylinder unloading valve groups, a connecting valve group, and an unloading valve group. Advantages include integrating multiple control functions for bidirectional pressurization, bidirectional pressing, connecting pressurization, and bidirectional pressure relief. This system ensures sufficient pressure and a fast pressurization speed in the upper and lower master cylinders of the bidirectional pressing hydraulic press, connects the upper chamber of the upper master cylinder with the lifting chamber of the lower master cylinder, maintains proportional pressure, and simultaneously relieves pressure in both chambers. This system is particularly suitable for various pressing processes for powdered materials and for pressing various molds. Not only does it have a reasonable structural design, accurate control, and high working efficiency, it can also greatly improve the quality of processed products and reduce the manufacturing cost of the hydraulic press.

[0004] Based on the above-mentioned existing technologies, the current hydraulic press pressure relief and unloading systems still have the following problems: the existing systems rely on a preset pressure threshold to trigger pressure relief, and are unable to predict the pressure change trend, resulting in pressure relief being too early or too late. In addition, the existing technologies mostly use accumulators to temporarily store hydraulic energy, but the energy conversion path is single, and it is unable to efficiently handle high-frequency, highly fluctuating pressure relief energy. At the same time, metal debris and colloidal impurities in the oil are easy to adhere to the valve core surface, which will cause sealing failure or action delay. For this reason, the present invention provides a hydraulic press pressure relief and unloading system. Summary of the Invention

[0005] In response to the shortcomings of the existing technology, the present invention provides a hydraulic press pressure relief and unloading system, which solves the following problems existing in the existing hydraulic press pressure relief and unloading system: the existing system relies on a preset pressure threshold to trigger pressure relief, and cannot predict the pressure change trend, resulting in pressure relief too early or too late. In addition, the existing technology mostly uses accumulators to temporarily store hydraulic energy, but the energy conversion path is single and cannot efficiently handle high-frequency and high-fluctuation pressure relief energy. At the same time, metal debris and colloidal impurities in the oil are easy to adhere to the valve core surface, which will cause sealing failure or delayed action.

[0006] To achieve the above objectives, the present invention is implemented through the following technical solutions: a hydraulic press pressure relief and unloading system, comprising a pressure relief and unloading system, wherein the pressure relief and unloading system comprises a power unit, an execution unit, a control unit, a pressure relief and unloading unit, and an auxiliary unit, wherein the output end of the power unit is fixedly connected to the input end of the execution unit, the execution unit and the control unit are bidirectionally connected, the output end of the auxiliary unit is fixedly connected to the input end of the power unit, and the output end of the pressure relief and unloading unit is fixedly connected to the input ends of the power unit and the auxiliary unit respectively;

[0007] The control unit includes a pressure sensor array, an edge computing module, an intelligent prediction module and a PLC main controller. The output end of the pressure sensor array is fixedly connected to the input end of the edge computing module, the output end of the edge computing module is fixedly connected to the input end of the intelligent prediction module, and the output end of the intelligent prediction module is fixedly connected to the input end of the PLC main controller.

[0008] Preferably, the power unit includes a variable frequency speed regulation main motor, a variable pump and a multi-way pressure sensor, the output end of the variable frequency speed regulation main motor is fixedly connected to the input end of the variable pump, and the output end of the variable pump is fixedly connected to the input end of the multi-way pressure sensor.

[0009] Preferably, the execution unit includes a hydraulic cylinder and a proportional reversing valve, and the output end of the hydraulic cylinder is fixedly connected to the input end of the proportional reversing valve.

[0010] Preferably, the pressure relief and unloading unit includes a multi-stage unloading valve group, an accumulator and an energy recovery module, and the output end of the multi-stage unloading valve group is fixedly connected to the input end of the accumulator and the energy recovery module.

[0011] Preferably, the auxiliary unit includes a high-precision filter and an oil temperature cooling system, and the output end of the high-precision filter is fixedly connected to the input end of the oil temperature cooling system.

[0012] Preferably, the multi-stage unloading valve group includes a modular self-cleaning valve core, an impurity monitoring sensor and an ultrasonic vibration unit, the output end of the modular self-cleaning valve core is fixedly connected to the input end of the impurity monitoring sensor, and the output end of the impurity monitoring sensor is fixedly connected to the input end of the ultrasonic vibration unit.

[0013] Preferably, the accumulator and energy recovery module includes a turbine power generation component, a hybrid energy storage component and an energy scheduling controller, the output end of the turbine power generation component is fixedly connected to the input end of the hybrid energy storage component, and the output end of the hybrid energy storage component is fixedly connected to the input end of the energy scheduling controller.

[0014] Preferably, the intelligent prediction module trains the AI model through historical pressure data, with a prediction error of less than 2%, and supports cloud-based model parameter updates.

[0015] The present invention provides a hydraulic press pressure relief and unloading system. Compared with the prior art, it has the following beneficial effects:

[0016] 1. The hydraulic press pressure relief and unloading system triggers pressure relief 10-50ms in advance through AI prediction in the intelligent prediction module, reducing invalid pressure holding time and lowering the main motor energy consumption by 12%-18%. By dynamically adjusting the pressure relief threshold, the pressure peak fluctuation range is reduced by 40%, and the service life of pipelines and seals is extended by more than 30%.

[0017] 2. The hydraulic press pressure relief and unloading system has a turbine power generation component efficiency of ≥65%, which is 25% higher than the traditional accumulator single recovery method. The 422 supercapacitors and lithium batteries work together to adapt to transient high-power loads, and the energy utilization rate is increased by 40%.

[0018] 3. The hydraulic press pressure relief and unloading system removes more than 90% of impurities on the valve core surface through an ultrasonic vibration unit, reducing the sticking failure rate by 80%. The impurity monitoring sensor provides real-time warning of the oil contamination level, avoiding excessive maintenance and extending the filter element replacement cycle by 2-3 times. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 This is a block diagram of the pressure relief and unloading system of the present invention;

[0020] Figure 2 This is a block diagram of the power unit of the present invention;

[0021] Figure 3 is a block diagram of an execution unit of the present invention;

[0022] Figure 4 is a block diagram of a control unit of the present invention;

[0023] Figure 5 This is a block diagram of the pressure relief and unloading unit of the present invention;

[0024] Figure 6 is a block diagram of the auxiliary unit of the present invention;

[0025] Figure 7 This is a block diagram of the multi-stage unloading valve assembly of the present invention;

[0026] Figure 8 This is a block diagram of the energy accumulator and energy recovery module of the present invention.

[0027] In the figure: 1-power unit, 11-frequency control main motor, 12-variable pump, 13-multi-channel pressure sensor, 2-execution unit, 21-hydraulic cylinder, 22-proportional reversing valve, 3-control unit, 31-pressure sensor array, 32-edge computing module, 33-intelligent prediction module, 34-PLC main controller, 4-pressure relief and unloading unit, 41-multi-stage unloading valve group, 411-modular self-cleaning valve core, 412-impurity monitoring sensor, 413-ultrasonic vibration unit, 42-accumulator and energy recovery module, 421-turbine power generation component, 422-hybrid energy storage component, 423-energy scheduling controller, 5-auxiliary unit, 51-high-precision filter, 52-oil temperature cooling system. DETAILED DESCRIPTION

[0028] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0029] See also Figures 1-8 , the present invention provides a technical solution:

[0030] A hydraulic press pressure relief and unloading system includes a pressure relief and unloading system, which includes a power unit 1, an execution unit 2, a control unit 3, a pressure relief and unloading unit 4, and an auxiliary unit 5. The output end of the power unit 1 is fixedly connected to the input end of the execution unit 2, the execution unit 2 and the control unit 3 are bidirectionally connected, the output end of the auxiliary unit 5 is fixedly connected to the input end of the power unit 1, and the output end of the pressure relief and unloading unit 4 is fixedly connected to the input ends of the power unit 1 and the auxiliary unit 5 respectively;

[0031] The control unit 3 includes a pressure sensor array 31, an edge computing module 32, an intelligent prediction module 33 and a PLC main controller 34. The output end of the pressure sensor array 31 is fixedly connected to the input end of the edge computing module 32, the output end of the edge computing module 32 is fixedly connected to the input end of the intelligent prediction module 33, and the output end of the intelligent prediction module 33 is fixedly connected to the input end of the PLC main controller 34.

[0032] Through AI prediction in the intelligent prediction module 33, pressure relief is triggered 10-50ms in advance, reducing invalid pressure holding time and lowering the energy consumption of the main motor by 12%-18%. By dynamically adjusting the pressure relief threshold, the pressure peak fluctuation range is reduced by 40%, and the service life of pipelines and seals is extended by more than 30%.

[0033] In this embodiment, the power unit 1 includes a variable frequency speed regulation main motor 11, a variable pump 12 and a multi-way pressure sensor 13. The output end of the variable frequency speed regulation main motor 11 is fixedly connected to the input end of the variable pump 12, and the output end of the variable pump 12 is fixedly connected to the input end of the multi-way pressure sensor 13.

[0034] The variable frequency speed regulation main motor dynamically adjusts its speed according to load demand, reducing ineffective power consumption at no load or low load by 10% to 15%. The variable pump 12 uses a pressure-flow composite control algorithm to match the execution unit requirements in real time and reduce overflow losses. The multi-channel pressure sensor 13 covers the main oil circuit and branch nodes to ensure comprehensive collection of pressure data and provide high-precision input for AI prediction.

[0035] In this embodiment, the execution unit 2 includes a hydraulic cylinder 21 and a proportional reversing valve 22 , and an output end of the hydraulic cylinder 21 is fixedly connected to an input end of the proportional reversing valve 22 .

[0036] The proportional reversing valve 22 achieves millimeter-level precision error of the movement speed and position of the hydraulic cylinder 21 less than 0.1mm through closed-loop control displacement sensor feedback, and the proportional valve electromagnetic drive response time is less than 10ms, avoiding the lag problem of traditional switching valves and improving production cycle efficiency.

[0037] In this embodiment, the pressure relief and unloading unit 4 includes a multi-stage unloading valve group 41 and an accumulator and energy recovery module 42 . The output end of the multi-stage unloading valve group 41 is fixedly connected to the input end of the accumulator and energy recovery module 42 .

[0038] The multi-stage unloading valve group 41 is opened in stages to avoid the instantaneous impact pressure fluctuation of the oil caused by the full opening of a single valve. The accumulator and energy recovery module 42 absorb the transient pressure fluctuation. The turbine power generation component 421 converts the remaining energy into electrical energy. The comprehensive energy recovery rate is ≥65%. The energy of the pressure relief process is quickly transferred through the recovery module, avoiding the sudden increase in oil temperature caused by excessive pressure relief in traditional systems.

[0039] In this embodiment, the auxiliary unit 5 includes a high-precision filter 51 and an oil cooling system 52 , and the output end of the high-precision filter 51 is fixedly connected to the input end of the oil cooling system 52 .

[0040] The high-precision filter 51 intercepts particles ≥5μm with a filtration efficiency of 99.9%, maintaining the NAS cleanliness level below level 8, reducing valve core wear. The oil temperature cooling system 52 adjusts the speed of the variable frequency fan according to the oil temperature sensor data, with an oil temperature fluctuation range of ±2°C and a viscosity stability improvement of 50%.

[0041] In this embodiment, the multi-stage unloading valve group 41 includes a modular self-cleaning valve core 411, an impurity monitoring sensor 412 and an ultrasonic vibration unit 413. The output end of the modular self-cleaning valve core 411 is fixedly connected to the input end of the impurity monitoring sensor 412, and the output end of the impurity monitoring sensor 412 is fixedly connected to the input end of the ultrasonic vibration unit 413.

[0042] The ultrasonic vibration unit 413 periodically removes impurities from the valve core surface with a cleaning efficiency of >90%, reducing the sticking failure rate by 80%. The impurity monitoring sensor 412 detects the oil particle concentration in real time, triggering cleaning or replacement of the valve core to avoid sudden failures. The modular self-cleaning valve core 411 can be replaced within 5 minutes, reducing downtime by 95% and ensuring production continuity.

[0043] In this embodiment, the accumulator and energy recovery module 42 includes a turbine power generation component 421, a hybrid energy storage component 422 and an energy scheduling controller 423. The output end of the turbine power generation component 421 is fixedly connected to the input end of the hybrid energy storage component 422, and the output end of the hybrid energy storage component 422 is fixedly connected to the input end of the energy scheduling controller 423.

[0044] The efficiency of the turbine power generation component 421 is ≥65%, which is 25% higher than the recovery rate of traditional accumulators. The hybrid energy storage component 422 is composed of a supercapacitor with a transient response of <5ms + a lithium battery for long-term energy storage, which can meet the periodic high-power demand of the hydraulic press. The energy scheduling controller 423 allocates electricity according to the peak and valley of grid electricity prices and the equipment load priority, and the comprehensive energy saving rate is increased to 35%.

[0045] In this embodiment, the intelligent prediction module 33 trains the AI model through historical pressure data, with a prediction error of less than 2%, and supports cloud-based model parameter updates.

[0046] The prediction error is less than 2%, and the pressure relief trigger time error is less than 10ms, avoiding energy waste caused by overpressure or premature pressure relief. The model is continuously optimized through historical data and cloud updates, and the adaptation time to different molds and material working conditions is shortened to within 1 hour.

[0047] Meanwhile, the contents not described in detail in this specification belong to the prior art known to those skilled in the art.

[0048] During operation, the variable frequency speed regulation main motor 11 drives the variable pump 12, and the oil enters the hydraulic circuit through the high-precision filter 51 to ensure the cleanliness of the oil. The PLC main controller 34 reads the preset working parameters such as target pressure and stroke, and the AI coprocessor synchronously loads the trained pressure prediction model. The edge computing module 32 completes the sensor calibration, and the proportional reversing valve 22 receives the PLC instruction to control the hydraulic cylinder to advance the workpiece at the set speed. The displacement sensor feeds back the position information in real time. The variable pump 12 dynamically adjusts the output according to the pressure-flow composite control algorithm to balance the load demand and energy consumption. The pressure sensor array 31 is distributed in the main oil circuit and the cylinder inlet and outlet to collect multi-position pressure data in real time and transmit it to the edge The computing module 32 uses machine learning algorithms such as LSTM time series prediction to analyze pressure change trends, predict the pressure peak within the next 10-50ms, and dynamically adjust the pressure relief trigger threshold. When the predicted pressure approaches the dynamic threshold, the PLC sends a command to the pressure relief unloading unit, synchronously opening the multi-stage unloading valve group 41. The accumulator and energy recovery module 42 instantly absorb the impact of the high-pressure oil and suppress pressure fluctuations. The high-pressure oil flows through the parallel-arranged turbine generator assembly 421, driving the generator to convert the fluid kinetic energy into electrical energy. The energy scheduling controller 423 distributes electricity according to load demand. The ultrasonic vibration unit 413 activates 20-40kHz ultrasonic waves every four hours or based on the impurity monitoring sensor feedback that the oil particle size is greater than ISO 18 / 16 to remove impurities attached to the valve core surface. The edge computing module 32 uploads pressure, energy consumption, and fault data to the cloud in real time. The AI model optimizes prediction accuracy through incremental learning. The energy scheduling controller 423 dynamically adjusts the energy storage strategy based on historical load data.

[0049] It should be noted that, in this document, relational terms such as first and second, etc., are used only 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 terms "comprises," "comprising," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that includes a list of elements includes not only those elements but also other elements not explicitly listed, or elements inherent to such process, method, article, or apparatus.

[0050] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A hydraulic press pressure relief and unloading system, comprising a pressure relief and unloading system, characterized in that: The pressure relief and unloading system comprises a power unit (1), an execution unit (2), a control unit (3), a pressure relief and unloading unit (4) and an auxiliary unit (5); the output end of the power unit (1) is fixedly connected to the input end of the execution unit (2); a bidirectional connection is achieved between the execution unit (2) and the control unit (3); the output end of the auxiliary unit (5) is fixedly connected to the input end of the power unit (1); and the output end of the pressure relief and unloading unit (4) is fixedly connected to the input ends of the power unit (1) and the auxiliary unit (5) respectively; The control unit (3) comprises a pressure sensor array (31), an edge computing module (32), an intelligent prediction module (33) and a PLC main controller (34); the output end of the pressure sensor array (31) is fixedly connected to the input end of the edge computing module (32); the output end of the edge computing module (32) is fixedly connected to the input end of the intelligent prediction module (33); and the output end of the intelligent prediction module (33) is fixedly connected to the input end of the PLC main controller (34).

2. A hydraulic press pressure relief and unloading system according to claim 1, characterized in that: The power unit (1) comprises a variable frequency speed regulating main motor (11), a variable pump (12) and a multi-channel pressure sensor (13); the output end of the variable frequency speed regulating main motor (11) is fixedly connected to the input end of the variable pump (12), and the output end of the variable pump (12) is fixedly connected to the input end of the multi-channel pressure sensor (13).

3. The hydraulic press pressure relief and unloading system according to claim 1, characterized in that: The execution unit (2) comprises a hydraulic cylinder (21) and a proportional reversing valve (22), wherein the output end of the hydraulic cylinder (21) is fixedly connected to the input end of the proportional reversing valve (22).

4. The hydraulic press pressure relief and unloading system according to claim 1, characterized in that: The pressure relief and unloading unit (4) comprises a multi-stage unloading valve group (41) and an accumulator and energy recovery module (42), wherein the output end of the multi-stage unloading valve group (41) is fixedly connected to the input end of the accumulator and energy recovery module (42).

5. The hydraulic press pressure relief and unloading system according to claim 1, characterized in that: The auxiliary unit (5) comprises a high-precision filter (51) and an oil temperature cooling system (52), and the output end of the high-precision filter (51) is fixedly connected to the input end of the oil temperature cooling system (52).

6. The hydraulic press pressure and load relief system according to claim 4, characterized in that: The multi-stage unloading valve group (41) comprises a modular self-cleaning valve core (411), an impurity monitoring sensor (412) and an ultrasonic vibration unit (413); the output end of the modular self-cleaning valve core (411) is fixedly connected to the input end of the impurity monitoring sensor (412), and the output end of the impurity monitoring sensor (412) is fixedly connected to the input end of the ultrasonic vibration unit (413).

7. The hydraulic press pressure and load relief system according to claim 4, characterized in that: The accumulator and energy recovery module (42) comprises a turbine power generation component (421), a hybrid energy storage component (422) and an energy scheduling controller (423), wherein the output end of the turbine power generation component (421) is fixedly connected to the input end of the hybrid energy storage component (422), and the output end of the hybrid energy storage component (422) is fixedly connected to the input end of the energy scheduling controller (423).

8. The hydraulic press pressure relief and unloading system according to claim 1, characterized in that: The intelligent prediction module (33) trains the AI model through historical pressure data, with a prediction error of less than 2%, and supports cloud-based model parameter updates.

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