Hydraulic Press Slide Runout Reduction
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Solution Overview
Problem
High-speed press machines face challenges in maintaining precision and reducing runout during high strokes per minute (SPM) operations, while being cost-effective and adaptable to varying product heights, due to complex mechanisms and limitations in hydraulic cylinder control.
Innovation Solution
A press machine design featuring multiple hydraulic pumps/motors connected in parallel to servomotors, with a stabilization controller and feedforward compensator, ensures stable operation, reduces moments of inertia, and allows for precise control of the slide position, enabling high SPM operations with reduced runout and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a mechanical press machine with dynamic balance retaining mechanism and special bearing mechanism is used to maintain high SPM, then the SPM can be maintained at 100-500, but the cost increases and the mechanism complexity increases
Solution Approach 1:
The patent replaces the traditional mechanical drive system (crankshaft, connecting rod, bearings) with a hydraulic cylinder directly connected to the slide. This eliminates the need for dynamic balance retaining mechanisms and special bearing mechanisms, simplifying the overall structure while maintaining high SPM capability through direct hydraulic actuation.
Solution Approach 2:
The patent employs a hydraulic cylinder as the primary drive mechanism for the slide, using hydraulic pressure to achieve high-speed reciprocating motion. This hydraulic approach replaces complex mechanical transmission systems, reducing the number of moving parts and eliminating the need for specialized high-speed mechanical components.
2Device complexity
If a hydraulic press machine with single hydraulic pump is used for high SPM operation, then the structure is simplified, but the control of slide position at high SPM is not practical
Solution Approach 1:
The patent divides the hydraulic drive system into multiple independent hydraulic pumps (first hydraulic pump and second hydraulic pump), each capable of independently controlling the slide position. This segmentation allows for precise control of slide position at high SPM while maintaining structural simplicity, as each pump can be controlled separately to achieve the desired motion profile.
3Device complexity
If a single hydraulic pump is used to drive the hydraulic cylinder, then the structure is simplified, but high SPM operation cannot be achieved
Solution Approach 1:
The patent employs multiple hydraulic pumps operating in parallel to drive the hydraulic cylinder, enabling high SPM operation. Each pump contributes to the overall hydraulic flow, allowing the system to achieve the high speeds required for 100-500 SPM while keeping each individual pump relatively simple in design.
Solution Approach 2:
The patent combines multiple hydraulic pumps into a unified drive system for the hydraulic cylinder. The pumps work together to provide the necessary hydraulic power for high-speed operation, merging their outputs to achieve the required flow rates and pressures for high SPM while maintaining structural simplicity through coordinated operation.
4Productivity
If a mechanical press machine is used, then high SPM can be achieved, but the slide runout increases reducing precision
Solution Approach 1:
The patent replaces the mechanical transmission system that causes slide runout with a direct hydraulic actuation system. The hydraulic cylinder is directly connected to the slide, eliminating intermediate mechanical components (crankshaft, connecting rod, bearings) that generate runout during high-speed operation, thereby maintaining manufacturing precision at high SPM.
Solution Approach 2:
The patent uses hydraulic pressure to directly drive the slide reciprocating motion, eliminating the mechanical transmission path that causes runout. The hydraulic system provides smooth, controlled motion without the inertial forces and mechanical clearances that lead to slide runout in mechanical press machines during high-speed operation.
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 design achieves precise and cost-effective high-speed press forming with minimal slide runout, allowing for flexible stroke adjustment and stable operation at high SPM, enhancing the machine's suitability for precise forming tasks.
Implementation Method 1
a first hydraulic pump/motor whose one port is connected to one pressure chamber (first pressurizing chamber) 30A of the hydraulic cylinder 30
Data Source
Figure 1
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AI summary
The press machine 1 includes: a hydraulic cylinder 30 configured to drive a slide 20; a plurality of hydraulic pumps/motors (P/M1 to P/M5); a first port of each of which is connected to a first pressurizing chamber 30A of the hydraulic cylinder 30; a plurality of servomotors (SM1 to SM5) axially connected to rotating shafts of the respective hydraulic pumps/motors (P/M1 to P/M5) respectively; a low-pressure accumulator 50 to which second ports of the hydraulic pumps/motors (P/M1 to P/M5) are each connected; a high-pressure accumulator 60 connected to a second pressurizing chamber 30B of the hydraulic cylinder 30; and a slide position controller 100 configured to control the servomotors (SM1 to SM5) so that a position of the slide matches a position corresponding to a slide position command signal based on the slide position command signal from a slide position commander and a slide position signal from a slide position detector 70.