Hydraulic Press Drive With Flywheel Energy Buffering
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Solution Overview
Problem
Existing hydraulic or oleodynamic presses face inefficiencies due to the use of large electric motors that operate at peak power during pressing periods and remain idle during waiting periods, leading to high energy consumption and potential power outages causing safety hazards.
Innovation Solution
A hydraulic or oleodynamic press equipped with a drive group that includes a variable flow pump and a flywheel system, allowing for the use of smaller electric motors and optimizing power usage by varying the flow rate and pressure based on the press's operational needs, ensuring continuous operation and safe extraction of objects even in power outages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If large electric motors are used to drive pumps during pressing periods, then sufficient power is available for pressing operations, but energy consumption increases significantly during waiting periods when no power is required
Solution Approach 1:
The patent applies a variable flow pump that can dynamically adjust its operation between different flow rates based on the press cycle requirements. During pressing periods, the pump operates at high flow rate to deliver sufficient power; during waiting periods, it reduces to zero or minimal flow rate, eliminating energy waste while maintaining system readiness.
Solution Approach 2:
The system implements periodic operation patterns where the pump alternates between active pressing phases and idle waiting phases. This periodic action allows the motor to be sized for peak power requirements while operating at reduced capacity during waiting periods, significantly reducing overall energy consumption.
2Reliability
If large electric motors are continuously operated to ensure power availability, then pressing operations can be maintained, but the system becomes vulnerable to power outages and safety hazards
Solution Approach 1:
The patent incorporates a flywheel that accumulates kinetic energy during waiting periods when the pump is not delivering flow. This stored energy is readily available during power outages to drive the pressing component and enable safe extraction of objects, providing emergency power without requiring continuous high-power motor operation.
Solution Approach 2:
The flywheel acts as an intermediary energy storage device between the motor and the pressing mechanism. It buffers power fluctuations, storing energy during normal operation and releasing it during power outages, thereby decoupling the motor's continuous operation from the pressing component's instantaneous power needs.
3Loss of energy
If pumps operate at zero flow rate during waiting periods, then energy consumption is reduced, but the system cannot respond quickly to pressing requirements
Solution Approach 1:
The flywheel is continuously accelerated during waiting periods to store kinetic energy in advance. This preliminary energy accumulation ensures that when pressing operations begin, the system can immediately deliver full power without delay, as the energy is already stored and ready for instant deployment.
Solution Approach 2:
While the pump flow rate varies between pressing and waiting periods, the flywheel maintains continuous rotation and energy storage throughout the cycle. This continuous action ensures uninterrupted power availability, eliminating response delays while allowing the pump to operate efficiently at variable flow rates.
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 solution enables efficient and economical operation with smaller motors, reduces energy waste, and ensures safe extraction of objects during power outages by maintaining continuous operation and optimizing power usage.
Implementation Method 1
A hydraulic or oleodynamic press equipped with a drive group that includes a variable flow pump and a flywheel system, allowing for the use of smaller electric motors and optimizing power usage
Data Source
AI summary
A hydraulic or oleodynamic or pneumatic press including a pressing component and a basic component or top component defining with the pressing component an area or pressing zone (PZ) in which to arrange pieces or objects (OB) to be machined.