Electro-Hydraulic Hybrid Press Machine Synchronization
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Solution Overview
Problem
Hydraulic press machines face inefficiencies due to low energy use efficiency, energy waste, noise, vibration, slow and unstable actuator movement, and low motion precision, leading to increased material and component consumption and energy consumption, while mechanical press machines lack flexibility and generate high energy consumption under the same pressing requirements.
Innovation Solution
An electro-hydraulic hybrid press machine with two vertical hydraulic cylinders and a common mechanical and hydraulic drive unit, utilizing a mechanical transmission structure to synchronize the movement of the cylinders and reduce energy loss, allowing for efficient energy utilization and improved control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydraulic press machine is used, then stable transmission and simple control are achieved, but energy use efficiency is low and energy waste occurs
Solution Approach 1:
The patent converts the harmful energy waste in hydraulic systems into beneficial energy by installing a regenerative braking system that captures kinetic energy during the downward movement of the press machine's movable beam. This regenerative energy is stored in a battery or capacitor and reused during upward movement, transforming waste energy into useful work and significantly improving overall energy efficiency while maintaining stable hydraulic transmission.
2Ease of operation
If hydraulic press machine is used, then simple control is achieved, but movement speed of actuator is slow and unstable
Solution Approach 1:
The patent implements a dynamic control system that combines hydraulic actuation with electric motor assistance. The system can dynamically switch between hydraulic mode for slow, precise movements and electric mode for fast, stable positioning. The controller adjusts the operation mode based on real-time process requirements, enabling the actuator to achieve both simple control and high-speed stable movement when needed.
3Reliability
If hydraulic press machine is used, then stable transmission is achieved, but motion precision is low
Solution Approach 1:
The patent introduces an intermediary positioning system that uses electric motors with high-resolution encoders as mediators between the hydraulic system and the movable beam. These electric actuators provide precise positioning control independent of the hydraulic system, while the hydraulic system maintains stable force transmission. The intermediary electric actuators compensate for hydraulic system variations and achieve high motion precision.
4Adaptability or versatility
If mechanical press machine is used, then flexibility is improved, but energy consumption is higher
Solution Approach 1:
The patent merges the advantages of hydraulic and mechanical systems by creating a hybrid press machine where a hydraulic system provides stable force transmission and mechanical linkages provide flexible motion control. The mechanical press machine's flexibility is retained through its linkage mechanisms, while energy consumption is reduced by using the hydraulic system's high efficiency for the bulk of the work and mechanical linkages only for motion transformation, rather than requiring high-power motors throughout the entire cycle.
5Productivity
If multiple press machines are used in production, then production capacity is increased, but material consumption and component use increase
Solution Approach 1:
The patent designs a press machine with multi-functional capabilities that can perform various forming operations using the same basic structure. The hydraulic system can be configured for different press tones and speeds, and the mechanical linkages can be adjusted for different motion patterns. This universality allows a single press machine to replace multiple specialized machines, increasing production capacity while reducing overall material consumption and component usage through shared structures and systems.
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
The electro-hydraulic hybrid press machine enhances working efficiency and accuracy, reduces material and component usage, and minimizes energy consumption by synchronizing the movement of hydraulic cylinders and utilizing mechanical transmission to convert and conserve energy.
Implementation Method 1
two vertical hydraulic cylinders are arranged in one press machine body
Implementation Method 2
the mechanical drive unit and moveable parts of two hydraulic cylinders form a linkage structure outside the cylinder body through a mechanical transmission structure
Data Source
AI summary
A press machine is provided. Two vertical hydraulic cylinders are arranged on an upper beam plate of a press machine body, and the two hydraulic cylinders correspond to workbenches at corresponding positions in a one-to-one correspondence, constituting left and right working units, and a common mechanical drive unit and a common hydraulic drive unit are set for the left and right working units. The mechanical driving unit is composed of a driving motor through an electromagnetic clutch, an electromagnetic brake and lead screw nut driving mechanism driven by a gear pair. According to the load profiles during the working process of hydraulic press machine, the mechanical driving unit or the hydraulic driving unit are selected to provide energy for the two working units. A control method for the press machine, a press machine execution system and a control method for the press machine execution system are further involved.