Hydraulic Extrusion Press Pressure-Side Integration for Faster Cycles
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Solution Overview
Problem
Hydraulic extrusion presses experience non-productive periods during backward movements and setup activities, leading to inefficiencies and increased operational costs due to the need for separate control pressure systems and pump designs that are not optimized for varying pressing forces and block sizes.
Innovation Solution
Integrating the main hydraulic line and control pressure system on the pressure side, allowing control oil to be used in the main line, and employing storage devices and proportional volume stream control to optimize oil distribution, reducing non-productive periods without increasing drive power or overall system design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate control pressure system is used to ensure operational reliability, then control pressure availability is improved, but device complexity and cost increase
Solution Approach 1:
The patent merges the control pressure system with the main hydraulic line by connecting them on the pressure side. The control pressure pumps draw oil from the main line and supply it back to the same main line, creating an integrated system that eliminates the need for completely separate hydraulic circuits while maintaining control pressure availability.
Solution Approach 2:
The control pressure pumps serve dual functions: they maintain control pressure for the valve controller and pump drives, and simultaneously contribute to the main hydraulic line by returning oil to it. This multi-functionality allows a single system to fulfill multiple roles, reducing overall system complexity.
2Reliability
If control pressure pumps are oversized to handle all phases including non-productive periods, then reliability is improved, but energy consumption increases
Solution Approach 1:
The patent implements dynamic pump operation where control pressure pumps are activated only when control pressure drops below a threshold value. This dynamic activation based on actual pressure needs allows the system to maintain reliability while minimizing energy consumption during non-productive periods when full pump capacity is not required.
Solution Approach 2:
The system changes operational parameters by adjusting pump activation thresholds and operating points based on actual system needs. During non-productive periods, pumps operate at lower power levels or remain idle until pressure drops, optimizing energy consumption while maintaining the ability to provide required control pressure when needed.
3Productivity
If the hydraulic system is designed for larger blocks, then productivity is improved, but control pressure pump utilization decreases
Solution Approach 1:
The system enables self-service by allowing the main hydraulic line to supply oil to the control pressure pumps, which then return it to the same line. This self-contained circulation allows the system to maintain control pressure without requiring external pumps to operate continuously, improving overall efficiency when processing larger blocks.
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 reduces non-productive periods by 0.5 to 0.8 seconds and allows for larger blocks to be pressed, maintaining operational reliability and cost-effectiveness by utilizing existing components and minimizing additional system design, while ensuring control pressure is always available.
Implementation Method 1
Hydraulic extrusion presses having a main hydraulic line that drives at least one ram as the main consumer
Implementation Method 2
a separate control pressure system, in order to ensure that a corresponding control pressure is available at all times, for example for a valve controller or pump drives
Data Source
AI summary
A hydraulic extrusion press includes at least one ram, the ram being driven by hydraulic oil from a main line and a hydraulic control pressure being used to control the extrusion press. To minimize non-productive periods, the control pressure is also supplied to the main line. The main line and the pressure control system are connected with one another on the pressure side.