Energy-saving system of servo machine tool

Abstract

The invention discloses an energy-saving system of a servo machine tool. The energy-saving system comprises an oil tank, an electric control cabinet, a driving device and an integrated valve group, the driving device is in transmission connection with a duplicate gear pump through a pump sleeve by a servo motor and is mounted on an oil tank, the integrated valve group is arranged on a mounting surface of the oil tank and comprises an integrated block, a direct-acting overflow valve, a pressure relay and a plurality of pressure measuring joints, and the direct-acting overflow valve, the pressure relay and the pressure measuring joints are inserted on the integrated block. Oil channels communicated with all the oil ports are formed in the integrated block, and a one-way valve, an unloading valve and other valve pieces are integrated in the integrated block. And the electric control cabinet is electrically connected with the driving device and the integrated valve group and is provided with an electric energy meter for monitoring energy consumption in real time. The dual gear pump is driven by the servo motor, pressure feedback and unloading control are combined, high-pressure and low-pressure dual-pump energy-saving oil supply is achieved, high-integration layout is adopted, pipeline connection is reduced, the compactness and stability of the system are improved, and the system is suitable for precision machining and small-scale operation scenes.

Description

Technical Field

[0001] This invention belongs to the field of servo machine tool control systems, specifically a servo machine tool energy-saving system. Background Technology

[0002] Traditional servo machine tool systems are widely used in precision machining and the assembly of micro-components. However, these systems are often hydraulically driven, which suffers from issues such as response lag and pressure fluctuations in hydraulic components. This makes it difficult to control positioning accuracy and fails to meet the machining and assembly requirements of micro-components such as precision valve cores and micro-sensor components. Furthermore, they suffer from poor integration, with their power units, control modules, and actuators often distributed, resulting in large space requirements and complex piping, hindering deployment in miniaturized environments. In terms of stability, traditional systems rely on hardware valves or pressure regulators for drive parameter adjustment, failing to achieve real-time, continuous digital control. This makes it difficult to adapt to the diverse process requirements of various workpiece sizes, and issues such as hydraulic oil leakage and component wear can lead to high equipment failure rates and increased maintenance costs. While existing servo-driven machine tools have addressed accuracy issues to some extent, they still suffer from low precision in the coordination between the actuator and power ends and redundant overall equipment size, making it difficult to balance precision and miniaturization. Finally, conventional servo machine tool systems cannot directly reflect energy consumption in terms of energy monitoring. Summary of the Invention

[0003] To address the shortcomings of existing technologies, this invention provides an energy-saving system for servo machine tools, including an oil tank. An electrical control cabinet is installed on one side of the oil tank. A drive device and an integrated valve assembly are also installed on the oil tank. The integrated valve assembly is located on one side of the mounting surface of the oil tank. The integrated valve assembly includes an integrated block and a direct-acting relief valve and a pressure relay inserted into the integrated block. A first pressure testing connector, a second pressure testing connector, a third pressure testing connector, and a fourth pressure testing connector are arranged side by side on the mounting surface of the integrated block. A first transition block and a first electromagnetic directional valve are superimposed on the first pressure testing connector. A second transition block and a second electromagnetic directional valve are superimposed on the second pressure testing connector. A third transition block and a third electromagnetic directional valve are superimposed on the third pressure testing connector. A fourth electromagnetic directional valve is superimposed on the fourth pressure testing connector.

[0004] Furthermore, the mounting surface of the integrated block is provided with several orifices: K1P, K1T, K1A and K1B are provided for the first pressure testing connector; K2P, K2T, K2A and K2B are provided for the second pressure testing connector; K3P, K3T, K3A and K3B are provided for the third pressure testing connector; and K4P, K4T, K4A and K4B are provided for the fourth pressure testing connector. Each orifice is provided with an extended oil passage within the integrated block.

[0005] Furthermore, the extended oil passages corresponding to ports K1A, K1B, K2A, K2B, K3A, K3B, K4A, and K4B on the integrated block are also provided with ports A1, B1, A2, B2, A3, B3, A4, and B4.

[0006] Furthermore, the integrated block is also equipped with a first oil inlet, a second oil inlet, a first oil return port, a second oil return port, an oil passage one, and an oil passage two. The outer mounting surface of the integrated block is also equipped with a direct-acting relief valve, a pressure relay, a first check valve, a second check valve, and an unloading valve.

[0007] Furthermore, oil passage one connects the first oil inlet and the second oil inlet, and is respectively connected to the first check valve, the second check valve, the pressure relay, the direct-acting relief valve and ports K1P, K2P, K3P, and K4P. The second check valve is connected to the second oil inlet, and an unloading valve is installed at the connection between the second check valve and the second oil inlet. The unloading valve is connected to the second return port. Oil passage two is respectively connected to ports K1T, K2T, K3T, K4T and the first return port.

[0008] Furthermore, the drive unit is installed on the upper mounting surface of the oil tank, and the electrical control cabinet is mounted on the side of the oil tank. The drive unit includes a servo motor and a pump sleeve and a double gear pump installed below the servo motor, which are assembled from top to bottom. The servo motor and the double gear pump are connected through the pump sleeve to realize the power output of the servo drive. The servo motor is installed on the upper mounting surface of the oil tank. The pump sleeve and the double gear pump are connected to the inside of the oil tank. The electrical control cabinet is electrically connected to the drive unit and the integrated valve group respectively.

[0009] Furthermore, an air filter, a liquid temperature regulator, a liquid level controller, and a liquid level gauge are also integrated on the mounting surface of the oil tank. The air filter is located at the top opening of the oil tank, the liquid temperature regulator is embedded in the side wall of the oil tank, and the liquid level controller and liquid level gauge are both installed on the side of the mounting surface of the oil tank near the electrical control cabinet. The liquid level controller is electrically connected to the electrical control cabinet to realize real-time monitoring and abnormal feedback of the liquid level in the oil tank.

[0010] Furthermore, pressure gauges are installed on all pressure testing connectors.

[0011] Furthermore, an energy meter is installed at the circuit inlet of the electrical control cabinet, which can monitor the amount of electricity used by the hydraulic system per unit time in real time.

[0012] Compared with existing technologies, this invention has the following characteristics and advantages: It uses a servo motor in the drive unit as the power core to drive a double gear pump, which, in conjunction with feedback elements such as pressure relays and first to fourth pressure testing connectors within the integrated valve group, forms a closed-loop linkage control with valves such as the direct-acting overflow valve and the first and second check valves on the integrated block; in terms of integrated compact design, the oil tank and its associated air filter, liquid temperature controller, level controller, and other accessories are integrated with the drive unit, integrated valve group, several transition blocks, and electromagnetic directional valves onto an oil tank with casters, simplifying external connection pipelines and improving deployment flexibility; digital control of each electromagnetic directional valve is achieved through an electrical control cabinet; and in terms of high stability maintenance, a servo motor-driven double gear pump replaces the traditional hydraulic pump... The integrated layout of the hydraulic power components and valve group reduces the risk of leakage. The valves on the integrated block use standardized interfaces and quick-release structures to reduce the difficulty of component replacement and thus reduce maintenance costs. A double gear pump is installed below the servo motor. When the system requires low pressure and high flow, the servo motor drives the double gear pump to achieve high flow. When the pressure reaches the required holding pressure, the large pump is unloaded through the unloading valve, and a pressure relay sends a signal to adjust the motor speed to a very low speed to ensure system pressure stability, thus overcoming system leakage and maintaining pressure. Then, the system switches to a small pump for high-pressure oil supply to achieve energy savings. An energy meter is installed at the circuit inlet in the electrical control cabinet to monitor the electricity consumption of the hydraulic system per unit time in real time. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is the left view of the present invention; Figure 3 This is a top view of the present invention; Figure 4 This is an internal component of the fuel tank according to the present invention; Figure 5 This is a schematic diagram of the overall structure of the integrated valve assembly of the present invention; Figure 6 This is a front view of the integrated valve body of the present invention; Figure 7 This is a left view of the integrated valve body of the present invention; Figure 8 This is a rear view of the integrated block of the present invention; Figure 9 This is a top view of the integrated block of the present invention; Figure 10 This is a bottom view of the integrated block of the present invention; Figure 11 This is a perspective view of the internal oil passages of the integrated block of the present invention.

[0014] in: 1-Fuel tank, 11-Air filter, 12-Liquid temperature controller, 13-Level controller, 14-Level gauge 2-Drive unit, 21-Servo motor, 22-Pump sleeve, 23-Double gear pump, 3-Integrated valve assembly; 31-Integrated block; 32-Direct-acting relief valve; 33-Pressure relay; 34-First check valve; 35-Second check valve; 36-Unloading valve; 301-First pressure test connector; 302-Second pressure test connector; 303-Third pressure test connector; 304-Fourth pressure test connector; 305-First transition block; 306-Second transition block; 307-Third transition block; 311-First oil inlet; 312-Second oil inlet; 313-First oil return port; 314-Second oil return port; 315-Oil passage one; 316-Oil passage two. 4-First solenoid directional valve, 5-Second solenoid directional valve, 6-Third solenoid directional valve, 7-Fourth solenoid directional valve 8-Electrical control cabinet. Detailed Implementation

[0015] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0016] like Figure 1-4 As shown, a servo machine tool energy-saving system comprises: an oil tank 1, a drive unit 2, an integrated valve group 3, and an electrical control cabinet 8. The oil tank 1 serves as the load-bearing foundation, with a flat upper mounting surface on its top. All core functional components are integrated and installed on this upper mounting surface and beside the oil tank 1, achieving a compact overall structure. The electrical control cabinet 8 is fixedly mounted beside the oil tank 1, used for centralized electrical control of the system's power output, valve group switching, and other actions. Both the drive unit 2 and the integrated valve group 3 are located on the upper mounting surface of the oil tank 1, with the integrated valve group 3 situated on one side of the upper mounting surface, forming a reasonable layout with the drive unit 2, facilitating oil circuit connection and reducing space occupation.

[0017] like Figure 5As shown, the integrated valve group 3 is the core component for centralized oil circuit control in this system. It uses an integrated block 31 as its mounting base, and all valves, pressure measuring components, and transition components are integrated onto this integrated block 31. The integrated block 31 has a rectangular block structure with various interconnected oil passages machined internally, and multiple mounting surfaces externally to accommodate the assembly of different components. A direct-acting relief valve 32 and a pressure relay 33 are fixedly installed on the upper mounting surface of the integrated block 31, spaced apart. The direct-acting relief valve 32 stabilizes the system oil circuit pressure, preventing damage to components from excessive pressure. The pressure relay 33 monitors the oil circuit pressure in real time and feeds the pressure signal back to the electrical control cabinet 8, enabling timely warning and control of pressure anomalies.

[0018] like Figure 2 , Figure 5-7 As shown, the upper mounting surface of the integrated block 31 has four pressure testing connectors arranged side-by-side along its length: a first pressure testing connector 301, a second pressure testing connector 302, a third pressure testing connector 303, and a fourth pressure testing connector 304. These four connectors have identical structures and are all used to connect external pressure gauges, allowing operators to monitor the pressure parameters of the corresponding oil circuits in real time. To accommodate the installation of the solenoid directional valves and the transition of the oil circuit, each pressure testing connector adopts a stacked assembly structure: the first pressure testing connector 301 has a first transition block 305 and a first solenoid directional valve 4 stacked sequentially from top to bottom; the second pressure testing connector 302 has a second transition block 306 and a second solenoid directional valve 5 stacked on it; the third pressure testing connector 303 has a third transition block 307 and a third solenoid directional valve 6 stacked on it; and the fourth pressure testing connector 304 has a fourth solenoid directional valve 7 directly stacked on it. The transition blocks allow for precise oil circuit connection between the pressure testing connectors and the corresponding solenoid directional valves, while also facilitating adaptation and adjustment according to the installation dimensions of different solenoid directional valves.

[0019] like Figure 8-11As shown, to achieve oil circuit connectivity among the components, the upper mounting surface of the integrated block 31 is machined with several orifices that communicate with the internal oil passages, and the orifices are arranged one-to-one with the four pressure testing connectors: the area corresponding to the first pressure testing connector 301 is provided with four orifices K1P, K1T, K1A and K1B; the area corresponding to the second pressure testing connector 302 is provided with four orifices K2P, K2T, K2A and K2B; the area corresponding to the third pressure testing connector 303 is provided with four orifices K3P, K3T, K3A and K3B; and the area corresponding to the fourth pressure testing connector 304 is provided with four orifices K4P, K4T, K4A and K4B. Each of the above-mentioned orifices has an extension oil passage corresponding to it inside the integrated block 31. The extension oil passages cooperate with each other to form a complete oil circuit network, realizing the distribution of pressure oil and the convergence of return oil. At the end of the extension oil passages corresponding to ports K1A, K1B, K2A, K2B, K3A, K3B, K4A and K4B on the integrated block 31, ports A1, B1, A2, B2, A3, B3, A4 and B4 are also provided respectively. This set of interfaces is the connection port of the external actuator of the system, used to connect the actuator and realize the conversion of oil circuit pressure energy into mechanical kinetic energy.

[0020] like Figure 8-11 As shown, the integrated block 31 also contains a core oil passage structure for connecting the main oil circuit, including a first oil inlet 311, a second oil inlet 312, a first oil return port 313, a second oil return port 314, an oil passage 1 315, and an oil passage 2 316. The first oil inlet 311 and the second oil inlet 312 are the system's pressure oil input ports, used to connect to the oil outlet of the drive device 2; the first oil return port 313 and the second oil return port 314 are the return oil output ports, used to guide the system's return oil back to the oil tank 1. Oil passage 315 serves as the main oil inlet channel, connecting at one end to the first oil inlet 311 and the second oil inlet 312, enabling the convergence and distribution of the two oil inlets. Simultaneously, oil passage 315 also connects to the first check valve 34, the second check valve 35, the pressure relay 33, the direct-acting relief valve 32, and ports K1P, K2P, K3P, and K4P, ensuring precise delivery of pressurized oil to the inlet ends of each solenoid directional valve and to pressure monitoring and stabilizing components; the second check valve 315... An unloading valve 36 is also provided at the connection between the directional valve 35 and the second oil inlet 312. The other end of the unloading valve 36 is connected to the second return oil port 314 to stabilize the pressure of the second oil inlet 312 and avoid pressure fluctuations from affecting the stability of the oil circuit. The second oil passage 316 serves as the main return oil passage. One end is connected to the K1T port, K2T port, K3T port, and K4T port respectively, and the other end is connected to the first return oil port 313, so that the return oil from each electromagnetic directional valve is converged and uniformly guided back to the oil tank 1.

[0021] like Figure 5-7As shown, a first check valve 34, a second check valve 35, and an unloading valve 36 are also installed on the outer mounting surface of the integrated block 31. The first check valve 34 and the second check valve 35 are used to prevent the backflow of pressurized oil in the oil passage and ensure the stability of the oil flow direction. The unloading valve 36 is used to balance the pressure at the oil inlet end and further improve the operational stability of the system.

[0022] like Figure 1-4 As shown, the drive unit 2 provides the power source for the system and is installed on the upper mounting surface of the oil tank 1. Specifically, it includes a servo motor 21, a pump sleeve 22, and a double gear pump 23, which are assembled sequentially from top to bottom. The servo motor 21 serves as the core of the power output and is fixedly installed on the upper mounting surface of the oil tank 1. Its output end is set downward and fixedly connected to the top of the pump sleeve 22. The pump sleeve 22 is fitted on the upper part of the double gear pump 23 and plays a role in sealing and positioning. Its bottom end is sealed to the upper mounting surface of the oil tank 1. The oil inlet end of the double gear pump 23 extends through the upper mounting surface of the oil tank 1 into the interior of the oil tank 1, and the oil outlet end is connected to the first oil inlet 311 and the second oil inlet 312 of the integrated block 31. The servo motor 21 and the double gear pump 23 are coaxially connected through the pump sleeve 22. After the servo motor 21 is started, it can drive the double gear pump 23 to rotate. The hydraulic oil in the oil tank 1 is drawn in and pressurized by the oil supply of the two pumps at low pressure and then output to the integrated valve group 3 at a large flow rate. Then, the small pump is switched to supply oil at high pressure to achieve precise power output of servo drive.

[0023] like Figure 1-4 As shown, the upper mounting surface of the oil tank 1 also integrates auxiliary components to ensure the normal operation of the system, including an air filter 11, a liquid temperature regulator 12, a liquid level controller 13, and a liquid level gauge 14. The air filter 11 is located at the top opening of the oil tank 1 to facilitate air exchange between the inside of the oil tank 1 and the outside environment, while filtering impurities in the air to prevent them from entering the oil tank 1 and contaminating the hydraulic oil. The temperature controller 12 is embedded inside the oil tank 1 to monitor and regulate the temperature of the hydraulic oil in the oil tank 1, ensuring that the hydraulic oil is within a suitable operating temperature range and guaranteeing the fluidity of the oil circuit and the lubrication effect of the components. The level controller 13 is installed on the mounting surface of the oil tank 1, and the level gauge 14 is installed on the side wall of the oil tank 1 near the electrical control cabinet 8. The level gauge 14 is used to visually display the hydraulic oil level in the oil tank 1 for easy observation by the staff. The level controller 13 is electrically connected to the electrical control cabinet 8 and can monitor the liquid level in the oil tank 1 in real time. When the liquid level is lower than the preset threshold, the level controller 13 sends a signal to the electrical control cabinet 8, which then issues a warning signal and controls the drive device 2 to stop working, preventing the double gear pump 23 from running dry and being damaged. This achieves real-time monitoring and abnormal feedback of the liquid level in the oil tank 1.

[0024] The electrical control cabinet 8 serves as the core of the system's control, integrating a controller, a touch-screen operating terminal, and various control circuits. It is electrically connected to the servo motor 21 of the drive unit 2, the pressure relay 33 of the integrated valve group 3, each directional valve, and the level controller 13. Operators can preset or adjust parameters such as the speed of the servo motor 21 and the switching frequency of each electromagnetic directional valve via the touch-screen operating terminal. The controller outputs control signals based on preset parameters or real-time commands: controlling the start, stop, and speed adjustment of the servo motor 21, thereby controlling the oil output and pressure of the double gear pump 23; controlling the on / off switching of each electromagnetic directional valve to achieve precise connection and switching of each oil circuit, thereby controlling the action of external actuators; simultaneously, the controller receives pressure signals from the pressure relay 33 and level signals from the level controller 13. When abnormal pressure or level is detected, it immediately executes warning or shutdown protection actions to ensure the safe and stable operation of the system. An energy meter is also installed at the circuit inlet of the electrical control cabinet 8, which allows for real-time monitoring of the electricity consumed by the hydraulic system per unit time.

Claims

1. A servo machine tool energy-saving system, comprising an oil tank (1), an electrical control cabinet (8) disposed on one side of the oil tank (1), and a drive device (2) and an integrated valve group (3) disposed on the oil tank (1), characterized in that: The integrated valve group (3) is located on one side of the mounting surface of the oil tank (1). The integrated valve group (3) includes an integrated block (31) and a direct-acting relief valve (32) and a pressure relay (33) inserted into the integrated block (31). The mounting surface of the integrated block (31) is provided with a first pressure tester (301), a second pressure tester (302), a third pressure tester (303) and a fourth pressure tester (304) arranged in parallel. A first transition block (305) and a first solenoid directional valve (4) are superimposed on the first pressure tester (301). A second transition block (306) and a second solenoid directional valve (5) are superimposed on the second pressure tester (302). A third transition block (307) and a third solenoid directional valve (6) are superimposed on the third pressure tester (303). A fourth solenoid directional valve (7) is superimposed on the fourth pressure tester (304).

2. The servo machine tool energy-saving system as described in claim 1, characterized in that: The mounting surface of the integrated block (31) is provided with several orifices: K1P, K1T, K1A and K1B are provided corresponding to the first pressure test connector (301); K2P, K2T, K2A and K2B are provided corresponding to the second pressure test connector (302); K3P, K3T, K3A and K3B are provided corresponding to the third pressure test connector (303); and K4P, K4T, K4A and K4B are provided corresponding to the fourth pressure test connector (304). Each orifice is provided with an extended oil passage within the integrated block (31).

3. The servo machine tool energy-saving system as described in claim 2, characterized in that: The integrated block (31) is further provided with extension oil passages corresponding to ports K1A, K1B, K2A, K2B, K3A, K3B, K4A and K4B, and ports A1, B1, A2, B2, A3, B3, A4 and B4.

4. The servo machine tool energy-saving system as described in claim 3, characterized in that: The integrated block (31) is also provided with a first oil inlet (311), a second oil inlet (312), a first oil return port (313), a second oil return port (314), an oil passage one (315), and an oil passage two (316). The outer mounting surface of the integrated block (31) is also provided with a direct-acting overflow valve (32), a pressure relay (33), a first check valve (34), a second check valve (35), and an unloading valve (36).

5. The servo machine tool energy-saving system as described in claim 4, characterized in that: The first oil passage (315) connects the first oil inlet (311) and the second oil inlet (312), and is respectively connected to the first check valve (34), the second check valve (35), the pressure relay (33), the direct-acting relief valve (32), and the K1P, K2P, K3P, and K4P ports. The second check valve (35) is connected to the second oil inlet (312), and an unloading valve (36) is provided at the connection between the second check valve (35) and the second oil inlet (312). The unloading valve (36) is connected to the second return oil port (314). The second oil passage (316) is respectively connected to the K1T port, K2T port, K3T port, K4T port and the first return oil port (313).

6. A servo machine tool energy-saving system as described in any one of claims 1-5, characterized in that: The drive unit (2) is installed on the upper mounting surface of the oil tank (1), and the electrical control cabinet (8) is mounted on the side of the oil tank (1). The drive unit (2) includes a servo motor (21) and a pump sleeve (22) and a double gear pump (23) arranged sequentially from top to bottom. The servo motor (21) and the double gear pump (23) are connected by the pump sleeve (22) to realize the power output of the servo drive. The servo motor (21) is mounted on the upper mounting surface of the oil tank (1). The pump sleeve (22) and the double gear pump (23) are connected to the inside of the oil tank (1). The electrical control cabinet (8) is electrically connected to the drive unit (2) and the integrated valve group (3) respectively.

7. The servo machine tool energy-saving system as described in claim 6, characterized in that: An air filter (11), a liquid temperature controller (12), a liquid level controller (13), and a liquid level gauge (14) are also integrated on the mounting surface of the oil tank (1). The air filter (11) is located at the top opening of the oil tank (1). The liquid temperature controller (12) is embedded in the side wall of the oil tank (1). The liquid level controller (13) and the liquid level gauge (14) are both installed on the side of the mounting surface of the oil tank (1) close to the electrical control cabinet (8). The liquid level controller (13) is electrically connected to the electrical control cabinet (8) to realize real-time monitoring and abnormal feedback of the liquid level in the oil tank (1).

8. The servo machine tool energy-saving system as described in claim 7, characterized in that: Pressure gauges are installed on all pressure testing connectors.

9. The servo machine tool energy-saving system as described in claim 8, characterized in that: An energy meter is installed at the circuit inlet of the electrical control cabinet (8), and the energy meter can monitor the amount of electricity used by the hydraulic system per unit time in real time.

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