Die Cushion Hydraulic Pre-Pressurization for Faster Force Response
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Solution Overview
Problem
Existing die cushion devices experience response delay and restricted die structure due to inability to control hydraulic pressure in the cap side hydraulic chamber before the slide and cushion pad collide, limiting the generation of desired die cushion force with high responsivity.
Innovation Solution
The die cushion device controls the fluid-pressure circuit to prevent operation fluid from flowing out from the rod side fluid-pressure chamber, allowing pressurization of the cap side fluid-pressure chamber before die cushion force control starts, which increases the responsivity of die cushion force generation without significantly restricting the die structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If die cushion force control starts only after slide and cushion pad collide, then die structure is less restricted, but response delay occurs and desired die cushion force cannot be generated promptly
Solution Approach 1:
The system performs preliminary pressurization of the cap side hydraulic chamber before the slide and cushion pad collide. The pressurization controller increases hydraulic pressure in advance, so when collision occurs, the die cushion force is already at or near the desired level, eliminating response delay without requiring significant cushion pad elevation
Solution Approach 2:
The pressurization controller continuously monitors the actual die cushion force and compares it with the target value, then adjusts the hydraulic pressure accordingly. This feedback mechanism ensures the die cushion force reaches the desired level promptly while adapting to actual operating conditions
2Reliability
If cushion pad is elevated by predetermined amount before collision, then die cushion force can be generated, but die structure is greatly restricted and practicality is reduced
Solution Approach 1:
The system uses hydraulic pressure control in the cap side hydraulic chamber to generate die cushion force, replacing the need for mechanical cushion pad elevation. By controlling hydraulic pressure, the desired die cushion force is achieved without physically elevating the cushion pad, thus avoiding restrictions on die structure
Solution Approach 2:
The system changes the parameter of hydraulic pressure in the cap side hydraulic chamber to generate the required die cushion force. Instead of changing the physical position of the cushion pad, the pressure parameter is adjusted to achieve the same effect, maintaining die structure practicality
3Speed
If hydraulic pressure control is implemented before collision, then responsivity is improved, but control complexity increases
Solution Approach 1:
The pressurization controller uses feedback control by continuously monitoring actual die cushion force and comparing it with the target value. This allows the system to automatically adjust hydraulic pressure without complex manual control, achieving high responsivity while keeping the control system manageable through automated feedback mechanisms
Solution Approach 2:
The control system is designed to autonomously manage the pressurization process. The pressurization controller automatically determines when to increase pressure and by how much, based on real-time feedback, eliminating the need for complex external control interventions and simplifying the overall control architecture
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables immediate generation of desired die cushion force at the die cushion standby position, enhancing responsivity and reducing the need for significant cushion pad elevation, thus improving the practicality of the die structure.
Implementation Method 1
a hydraulic cylinder (fluid-pressure cylinder) that supports the cushion pad to generate die cushion force
Data Source
Figure 1
Figure 2
Figure 3(A)~3(D)
AI summary
A die cushion device 100 includes a hydraulic cylinder 120 that supports a cushion pad 110 and generates die cushion force when the slide 14 of the press machine 10 descends, a first hydraulic circuit 130 connected to a cap side hydraulic chamber 120a of the hydraulic cylinder 120, and a second hydraulic circuit 140 connected to a rod side hydraulic chamber 120b. Before die cushion force control starts, the second hydraulic circuit 140 causes hydraulic oil in the rod side hydraulic chamber 120b to be prevented from flowing out, and the first hydraulic circuit 130 causes the cap side hydraulic chamber 120a to be pressurized.