A hydraulic press system and operation method thereof

Abstract

The invention relates to a hydraulic press (100), especially for use in the production of aluminum cast parts, which allows the hydraulic oil to be isolated from the atmosphere and to the working method of this system. More specifically, the present invention relates to a nitrogen tank (6) connected to the hydraulic oil tank (8) with a connection pipe (9) that allows the hydraulic oil used in the system to remain clean, and a hydraulic press (100) system and working method that provides a solution to the problem of dust and abrasive substances or any other parts entering the hydraulic oil, which is experienced in the state of the art, thanks to the nitrogen tank (6).

Description

[0001] A HYDRAULIC PRESS SYSTEM AND OPERATION METHOD THEREOF

[0002] Technical Field

[0003] The invention relates to a hydraulic press system, especially for use in the production of aluminum cast parts, which allows the hydraulic oil to be isolated from the atmosphere and to the working method of this system.

[0004] More specifically, the present invention relates to a nitrogen tank connected to the hydraulic oil tank with a connection pipe that allows the hydraulic oil used in the system to remain clean, and a hydraulic press system and working method that provides a solution to the problem of dust and abrasive substances or any other parts entering the hydraulic oil, which is experienced in the state of the art, thanks to the nitrogen tank.

[0005] Prior Art

[0006] Today, aluminum casting parts are produced using metal injection machines. In this method, molten aluminum is injected into molds by applying pressure using injection machines. Thus, the casting process is carried out. In addition, thanks to the high pressure applied to the molten aluminum, a large amount of aluminum is filled into the mold very quickly. High pressure continues to be applied to the liquid aluminum in the mold until solidification is complete. After solidification is complete, the mold is opened and the aluminum part is removed from the mold with the help of push rods.

[0007] In the state of the art, the use of metal injection molding machines is quite complex and costly. Since these injection molding machines are produced by the closed mold method, there are runners for the molten liquid to move through the mold. These runners make mold design more complex and increase process times and mold costs. Since metal injection molding machines use closed molds, the air trapped in the mold poses a problem for the crystal structure of the product to be pressed and for the coatings to be applied to the product. In addition, for large and thick aluminum parts, the metal injection method causes the production area to expand and thus increase the production cost. In another known state of the art, the foundries where aluminum casting parts are produced are generally dusty and abrasive. Such dust and abrasive materials cause contamination of the hydraulic oil used in the system during production. Therefore, the system hydraulics are damaged and cannot be used for a long time.

[0008] In the utility model document number CN209614192U, describes a differential die casting machine. In this document, a sealing cover is placed on the outside of the mold, a movable plate is placed at the upper end of the mold, a top plate is placed on top of the movable plate, lifting support columns are placed on the four end legs of the movable plate and top plate, and a vertical lifting piston is placed in the middle of the movable plate and top plate. However, there is no mention here of a hydraulic press system that uses a nitrogen tank to protect the hydraulic oil from dust and abrasives.

[0009] In the patent document number CN115625923A, mention is made herein of an aluminum alloy die-casting press mounting mechanism comprising a fixed machine box, wherein a fixed support is fixedly connected to the interior of the fixed machine box, wherein a mounting support is arranged on the upper part of the fixed support. However, there is no mention herein of a hydraulic press system for protecting hydraulic oil from dust and abrasive substances by using a nitrogen tank.

[0010] In the utility model document number CN211161867U, describes a low-pressure die casting machine for producing and processing aluminum alloys. The casting machine comprises a casting machine body and a hydraulic telescopic rod, wherein an upper mold and a lower mold are arranged on the side wall of the upper end of the casting machine body. However, there is no mention here of a hydraulic press system, whereby a nitrogen tank is used to protect the hydraulic oil from dust and abrasive substances.

[0011] As a result, the need arose for the solution in question, which enables a hydraulic press system and a method of operation to protect hydraulic oil from dust and abrasive materials and to produce larger and thicker aluminum parts at lower costs.

[0012] Objectives and Brief Description of the Invention

[0013] The main purpose of the present invention to protect the hydraulic oil used in the system from dust and abrasive substances and to ensure the long-term use of the system hydraulics. Other objects of the invention are as follows;

[0014] - producing larger and thicker aluminum casting parts at lower cost,

[0015] - preventing corrosion in tanks by using nitrogen tanks,

[0016] - to obtain a closed hydraulic cycle isolated from the atmosphere thanks to the nitrogen tank, and also to obtain a system resistant to burning since there are no oxygen molecules in the system.

[0017] On the other hand, the operation of the hydraulic press system, which is the subject of the invention, is simpler than the metal injection machines used in the known state of the art. Therefore, operators need less training in use and maintenance. This increases business continuity.

[0018] In order to achieve the aforesaid aims, the invention is a hydraulic press system that comprises a main body, a hydraulic cylinder group positioned on this main body, a hydraulic mold group, a motor that provides movement to the system and a hydraulic oil tank, wherein

[0019] - comprising at least one nitrogen tank connected with the hydraulic oil tank, and

[0020] - the hydraulic oil tank and the nitrogen tank together form a closed loop isolated from the atmosphere.

[0021] In the preferred embodiment of the invention, the nitrogen tank and the hydraulic oil tank are positioned on opposite sides of the main body.

[0022] In another preferred embodiment of the invention, the hydraulic oil tank and the nitrogen tank are connected by means of at least one connection pipe.

[0023] In another embodiment of the invention, the nitrogen tank having a gas pressure in the range of 0,75 - 1 ,5 bar.

[0024] On the other hand, the hydraulic mold group comprises a fixed plate on which the mold is placed, a movable plate that compresses the raw material placed in the mold with the force it applies to obtain the final product, and an extractor element that pushes the pressed product out of the mold by means of the shaft inside.

[0025] The hydraulic cylinder group comprises a main cylinder and a main piston connected to the main cylinder. The hydraulic press system according to the invention further comprises directional control valves for delivering hydraulic oil to the hydraulic cylinder assembly and to the hydraulic mold assembly.

[0026] The invention also relates to a method of operation of a hydraulic press system;

[0027] - in the case where the main piston moves downwards during the mold pressing phase, passing of nitrogen gas from the nitrogen tank to the hydraulic oil tank in the amount of the hydraulic oil volume lost from the hydraulic oil tank, and as a result of this process, decreasing of the gas pressure in the nitrogen tank to a minimum level, in the case where the main piston moves upwards after the mold pressing is completed, passing of the nitrogen gas, whose pressure increases due to the increase in the oil volume in the hydraulic oil tank, into the nitrogen tank with lower pressure, and as a result of this process, reaching of the gas pressure maximum level in the nitrogen tank.

[0028] Brief Description of the Figures

[0029] Figure 1 shows an isometric view of the inventive hydraulic press system.

[0030] Figure 2 shows the front view of the inventive hydraulic press system.

[0031] Figure 3 shows a side view of the inventive hydraulic press system.

[0032] Figure 4 shows the hydraulic schematic of the inventive hydraulic press system.

[0033] Reference Numbers

[0034] 100. Hydraulic press

[0035] 101. Main body

[0036] 1. Extractor element

[0037] 2. Fixed plate

[0038] 3. Movable plate

[0039] 4. Main cylinder 5. Main piston

[0040] 6. Nitrogen tank

[0041] 7. Motor

[0042] 8. Hydraulic oil tank

[0043] 9. Connection pipe

[0044] 10. Safety valve

[0045] 11. Pressure safety valve

[0046] V. Directional control valve

[0047] Detailed Description of the Invention

[0048] The present invention discloses a hydraulic press (100) system for use in the production of cast aluminum parts, in particular for use in the production of cast aluminum parts, which allows the hydraulic oil to be isolated from the atmosphere, and a method of operation of this system.

[0049] The inventive hydraulic press (100) system is shown in Figures 1 , 2 and 3. Figure 1 shows an isometric view of the hydraulic press (100) system, Figure 2 shows a front view and Figure 3 shows a side view.

[0050] As shown in Figures 1 and 2, the hydraulic press (100) system comprises a main body (101 ) having a monolithic structure on which the hydraulic mold group and the hydraulic cylinder group are positioned. The hydraulic mold group comprises a fixed plate (2) on which the mold is placed, a movable plate (3) that allows the final product to be obtained by compressing the raw material placed in the mold with the force it applies, and an extractor element (1 ) that pushes the pressed product out of the mold by means of the shaft inside. The hydraulic cylinder assembly comprises a main cylinder (4) and a main piston (5) connected to the main cylinder (4).

[0051] The hydraulic press (100) system according to the invention comprises directional control valves (V) for delivering hydraulic oil to the hydraulic mold group and hydraulic cylinder group. In the preferred embodiment of the invention, the directional control valves (V) may be, but are not limited to, solenoid valves and / or pneumatic valves and / or miniature motorized ball valves. The invention relates to a hydraulic press (100) system comprising a motor (7) and a hydraulic oil tank (8) providing motion to the system,

[0052] - comprising at least one nitrogen tank (6) connected to the hydraulic oil tank (8) and

[0053] - the hydraulic oil tank (8) and the nitrogen tank (6) together form a closed cycle isolated from the atmosphere.

[0054] The inventive hydraulic press (100) system comprises at least one connection pipe (9) for connecting the hydraulic oil tank (8) and the nitrogen tank (6). In the preferred embodiment of the present invention, the connection pipe (9) is used for gas exchange between the hydraulic oil tank (8) and the nitrogen tank (6) to obtain a closed cycle within the system. Unlike the preferred embodiment, the length of the connection pipe (9) can be shortened to a predetermined extent to enable faster gas exchange between the two tanks. In this way, the way and position of the nitrogen tank (6) to the hydraulic oil tank (8) can be changed. As a result of this process, the gas exchange between the two tanks is faster, thus saving time.

[0055] For the downward movement of the movable plate (3) mentioned in the above paragraphs, hydraulic oil is first supplied to the system by means of pumps operating with the help of the motor (7). By supplying hydraulic oil to the system in question, the directional control valves (V) are triggered. Hydraulic oil is transmitted to the main cylinder (4) through the aforementioned directional control valves (V) and a compression force is generated here by driving the main cylinder (4). The main piston (5) is driven by the compression force. When the main piston (5) is driven, the movable plate (3) moves downwards in direct proportion to the main piston (5). During this process, nitrogen gas passes from the nitrogen tank (6) to the hydraulic oil tank (8) in the amount of the hydraulic oil volume that decreases from the hydraulic oil tank (8), and as a result of this process, the gas pressure in the nitrogen tank (6) drops to the minimum level.

[0056] When the movable plate (3) moves upwards, the directional control valves (V) are triggered again by the motor (7). The hydraulic oil in the main cylinder (4) is transmitted to the hydraulic oil tank (8) through the directional control valves (V). And during this process, the movable plate (3) moves upwards in direct proportion to the main piston (5) connected to the main cylinder (4). As the movable plate (3) moves upwards, the oil volume in the hydraulic oil tank (8) increases and, accordingly, the nitrogen gas pressure in the tank increases. The nitrogen gas with increasing pressure passes to the nitrogen tank (6) which has lower pressure and as a result of this process, the gas pressure in the nitrogen tank (6) reaches the maximum level.

[0057] The cycle in question occurs with each upward and downward movement of the movable plate (3) mentioned in the above paragraphs.

[0058] On the other hand, since the amount and pressure of hydraulic oil sent to the main cylinder (4) can be controlled by the hydraulic system software, the up and down speed and tonnage of the movable plate (3) can be adjusted at desired values.

[0059] The hydraulic scheme and components of the hydraulic press (100) system of the invention are shown in Figure 4. The process steps in the working process of the system in question are as follows;

[0060] - in the first step, connecting the product mold to the fixed plate (2) and the movable plate (3),

[0061] - in the second step, hydraulic oil is supplied to the system through pumps driven by the motor (7) and the directional control valves (V) are triggered,

[0062] - in the third step, hydraulic oil is delivered to the main cylinder (4) via the directional control valves (V) and the main cylinder (4) is actuated to create a compression force there,

[0063] - in the fourth step, the main piston (5) is driven by the mentioned compression force,

[0064] - in the fifth step, the movable plate (3) moves downwards in direct proportion to the main piston (5) when the main piston (5) is actuated,

[0065] - during the third step, nitrogen gas passes from the nitrogen tank (6) to the hydraulic oil tank (8) as much as the volume of hydraulic oil missing from the hydraulic oil tank (8) and as a result of this process, the gas pressure in the nitrogen tank (6) drops to a minimum level, and / or - in the sixth step, the directional control valves (V) are triggered again by the motor (7),

[0066] - in the seventh step, the hydraulic oil in the main cylinder (4) is delivered to the hydraulic oil tank (8) via the directional control valves (V),

[0067] - during the seventh step, the movable plate (3) moves upwards in direct proportion to the main piston (5) connected to the main cylinder (4),

[0068] - in the eighth step, an increase in the nitrogen gas pressure due to an increase in the oil volume in the hydraulic oil tank (8) during the upward movement of the movable plate (3),

[0069] - in the ninth step, the nitrogen gas with increased pressure passes into the nitrogen tank (6) with lower pressure and as a result of this process, the gas pressure in the nitrogen tank (6) reaches the maximum level comprises process steps.

[0070] On the other hand, the hydraulic press (100) is the preferred method of operation;

[0071] - in the case where the main piston (5) moves downwards during the mold pressing phase, passing of nitrogen gas from the nitrogen tank (6) to the hydraulic oil tank (8) in the amount of the hydraulic oil volume lost from the hydraulic oil tank (8), and as a result of this process, decreasing of the gas pressure in the nitrogen tank (6) to a minimum level,

[0072] - in the case where the main piston (5) moves upwards after the mold pressing is completed, passing of the nitrogen gas, whose pressure increases due to the increase in the oil volume in the hydraulic oil tank (8), into the nitrogen tank (6) with lower pressure, and as a result of this process, reaching of the gas pressure maximum level in the nitrogen tank (6).

[0073] On the other hand, the inventive hydraulic press (100) system comprises a safety valve (10) protecting the press system from high pressure and a pressure safety valve (11 ) regulating the pressure in the system.

[0074] A comparative table of the hydraulic press dimensions used in the present art and the invention is given below:

[0075] As seen in the table above, the motor power of the hydraulic press dimensions known in the current technique is 45 kW, the press tonnage is 200 tons, the main cylinder stroke is 800 mm, the full opening is 1200 mm, the press usage area is 1200x1200 mm and the lower extractor stroke distance is 160 mm. The large size of the press utilization area in question narrows the working area of the companies currently engaged in this business. In addition, due to the narrow working area, press maintenance and repair works take a short time. On the other hand, the dimensions of the hydraulic press used in the invention are; motor power 22 kW, press tonnage 400 tons, main cylinder stroke 400 mm, full opening 885 mm, lower extractor stroke distance 130 mm and press usage area 870x600 mm. Our invention, which has these special dimensions, provides a solution to the problems experienced in the existing technique. For example; the press area in the present invention takes up less space than the press area mentioned in the prior art. In this way, the operators will have a comfortable working area and there will be an opening where the operator can work comfortably around the press. In addition, since the hydraulic press used in the invention has a vertical construction, it has a rigid body and is suitable for robot automation.

Claims

CLAIMS1. A hydraulic press (100) system comprising a main body (101 ), a hydraulic cylinder group positioned on this main body (101 ), a hydraulic mold group, a motor (7) providing movement to the system and a hydraulic oil tank (8), characterized by- comprising at least one nitrogen tank (6) connected with the hydraulic oil tank (8), and- the hydraulic oil tank (8) and the nitrogen tank (6) together form a closed loop isolated from the atmosphere.

2. The hydraulic press (100) system according to claim 1 , wherein the nitrogen tank (6) and the hydraulic oil tank (8) are positioned on opposite sides of the main body (101 ).

3. The hydraulic press (100) system according to claim 1 or 2, wherein the hydraulic oil tank (8) and the nitrogen tank (6) are connected by means of at least one connection pipe (9).

4. The hydraulic press (100) system according to any one of the preceding claims, wherein the nitrogen tank (6) having a gas pressure in the range of 0,75 - 1 ,5 bar.

5. The hydraulic press (100) system according to any one of the preceding claims, characterized by the hydraulic mold assembly comprises a fixed plate (2) on which the mold is placed, a movable plate (3) which allows the final product to be obtained by compressing the raw material placed in the mold with the force it applies, and an ejector element (1 ) which ejects the pressed product from the mold by pushing it by means of a shaft inside.

6. The hydraulic press (100) system according to any one of the preceding claims, wherein the hydraulic cylinder assembly comprises a main cylinder (4) and a main piston (5) connected to the main cylinder (4).

7. The hydraulic press (100) system according to any one of the preceding claims, wherein it comprises directional control valves (V) for delivering hydraulic oil to the hydraulic cylinder assembly and to the hydraulic mold assembly.

8. A working method of a hydraulic press (100), characterized by- in the case where the main piston (5) moves downwards during the mold pressing phase, passing of nitrogen gas from the nitrogen tank (6) to the hydraulic oil tank (8) in the amount of the hydraulic oil volume lost from the hydraulic oil tank (8), and as a result of this process, decreasing of the gas pressure in the nitrogen tank (6) to a minimum level,- in the case where the main piston (5) moves upwards after the mold pressing is completed, passing of the nitrogen gas, whose pressure increases due to the increase in the oil volume in the hydraulic oil tank (8), into the nitrogen tank (6) with lower pressure, and as a result of this process, reaching of the gas pressure maximum level in the nitrogen tank (6).

9. The method of operation of the hydraulic press (100) according to claim 8, wherein the nitrogen tank (6) gas pressure is in the range of 0,75 - 1 ,5 bar.

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