Free Forging Hydraulic Press With Alternating Pressure Energy Storage
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Solution Overview
Problem
Conventional free forging hydraulic presses waste energy due to long-term idling of hydraulic pumps, which are required to provide high power for heavy forgings, leading to inefficient resource utilization and energy wastage.
Innovation Solution
The implementation of a high-efficiency transmission free forging hydraulic press with pressurization energy storage apparatuses and a control system that allows for low-pressure energy storage and high-pressure output, using electromagnetic valves and displacement sensors to alternate energy storage and supply to the hydraulic cylinder, ensuring continuous and efficient energy use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple high-power hydraulic pumps are provided to meet the power requirements for heavy forgings, then the power supply capability is improved, but energy waste increases due to long-term idling
Solution Approach 1:
The energy storage tank stores hydraulic energy in advance during low-demand periods (idling phases), so that when high power is needed for forging operations, the stored energy is released to supplement the hydraulic pump output, avoiding the need for the pump to continuously operate at high power and thus reducing energy waste during idle periods
Solution Approach 2:
The system operates in periodic cycles where the hydraulic pump alternates between working phases (supplying power during forging) and idle phases (recharging the energy storage tank), creating a rhythmic operation pattern that reduces overall energy consumption while maintaining adequate power supply capability
2Speed
If the hydraulic pump operates continuously to maintain linear speed for forging, then the forging speed requirement is met, but electric power resource is wasted
Solution Approach 1:
The energy storage tank acts as an intermediary between the hydraulic pump and the hammerhead, buffering the speed variations by releasing stored energy during rapid descent phases and absorbing energy during return stroke phases, thereby maintaining the required linear speed without continuous high-power pump operation
Solution Approach 2:
The system changes the operating parameters of the hydraulic pump by allowing it to operate at variable speeds and pressures rather than maintaining constant high-power output, using the energy storage tank to compensate for parameter variations and maintain the required forging linear speed
3Power
If the hydraulic pump is configured to meet peak power demands, then the peak power requirement is satisfied, but energy waste increases during low-demand idle periods
Solution Approach 1:
The energy storage tank is charged in advance during idle periods when power demand is low, storing hydraulic energy that will be released during peak demand forging operations, allowing the pump to operate at lower power levels during idle times while still meeting peak power requirements when needed
Solution Approach 2:
The system transitions from a static high-power pump configuration to a dynamic system where the pump power output varies with demand, supplemented by the energy storage tank that dynamically releases or absorbs energy to maintain adequate power supply during both peak and idle periods
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 solution reduces resource configuration needs, enhances transmission efficiency, and conserves energy by allowing the hydraulic cylinder to operate with high pressure even when the pump is at low pressure, achieving surplus energy storage and efficient transmission.
Implementation Method 1
by providing a pressurization energy storage apparatus in a hydraulic circuit, achieves an objective of low-pressure energy storage and high-pressure output for hydraulic power oil
Implementation Method 2
the hydraulic press can store energy both in operation and in idleness, thereby realizing storage of surplus energy
Data Source
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AI summary
The present disclosure relates to a high-efficiency transmission free forging hydraulic press and an operation method thereof. The high-efficiency transmission free forging hydraulic press comprises: a hydraulic cylinder, a hydraulic pump, and a pressurization energy storage apparatus. By providing two pressurization energy storage apparatuses between the hydraulic pump and the hydraulic cylinder of the high-efficiency transmission free forging hydraulic press, under the effect of a control system, the two pressurization energy storage apparatuses can alternately provide isobaric pressure oil or pressure oil having undergone pressurization to the hydraulic cylinder of the free forging hydraulic press, such that when the hydraulic pump operates in a status with a relatively low pressure, the hydraulic cylinder in the free forging hydraulic press can constantly obtain the isobaric pressure oil or the pressurization pressure oil, achieving the object of storage of surplus energy and high-efficiency transmission of the hydraulic press. The high-efficiency transmission free forging hydraulic press is reasonable in resource configuration, simple in provision structure, good in pressurization effect, and energy-saving and consumption-reducing.