Hydraulic Rolling Machine Accumulator Segmentation
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Solution Overview
Problem
Rolling machines with hydraulic actuation for forming impressions on cylindrical bodies face high oil consumption, significant electricity costs for the circulation pump, and energy usage for cooling, which increase operational costs.
Innovation Solution
The rolling machine employs a hydraulic system with bladder accumulators and a logic control unit to manage oil flow efficiently, using two accumulators with different pressure ranges for approaching and working travels, and a circulation pump that operates only when necessary to charge the accumulators, reducing continuous oil recirculation and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hydraulic system with continuous oil recirculation is used to drive forming rollers during both approaching and work travels, then the forming rollers can be moved reliably along the entire cycle, but oil consumption and electricity costs for the circulation pump increase significantly
Solution Approach 1:
The hydraulic system is segmented into two independent circuits: a first hydraulic circuit with a first circulation pump for the approaching travel, and a second hydraulic circuit with a second circulation pump for the work travel. This allows each pump to operate independently and only when needed, reducing overall energy consumption while maintaining reliable movement during both phases of the forming roller cycle.
2Speed
If a single high-flow circulation pump is used to supply oil during approaching travel, then the forming rollers can be moved quickly to position, but the pump consumes excessive electricity and requires costly cooling systems
Solution Approach 1:
The single high-power circulation pump is segmented into two separate pumps: a first circulation pump with lower power rating dedicated to the approaching travel, and a second circulation pump for the work travel. The first pump is sized appropriately for the higher flow requirements of the approaching phase without needing to be oversized for the work phase, reducing electricity consumption and cooling requirements while maintaining the necessary speed for positioning.
3Ease of operation
If continuous oil recirculation is maintained throughout the entire operating cycle, then the hydraulic system remains ready for immediate action, but oil consumption increases and environmental harm is caused
Solution Approach 1:
Instead of continuous recirculation, the system uses periodic action where the first circulation pump operates only during the approaching travel phase and the second circulation pump operates only during the work travel phase. This intermittent operation reduces oil consumption and environmental impact while maintaining system readiness through proper timing and control of each pump's operation during its designated phase.
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 decreases oil consumption and electrical energy usage, lowering operating costs while maintaining the precision and effectiveness of the rolling process for forming impressions on cylindrical bodies.
Implementation Method 1
The rolling machine (1) employs a hydraulic system (100) with bladder accumulators and a logic control unit to manage oil flow efficiently, using two accumulators with different pressure ranges for approaching and working travels
Implementation Method 2
A first interception valve (108) mounted on the first supply duct (202) which is capable of controlling the hydraulic supply from the first accumulator (106) to the hydraulic actuators (15)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Rolling machine with hydraulic actuation, which comprises two or more forming rollers (6), mechanically associated with the support structure (2) and adapted to plastically deform a cylindrical body arranged along a central work axis (A) of the machine (1). Each forming roller (6) is provided with a shaped profile and is driven to rotate around its rotation axis (Z) by a brushless motor (16) and is driven to be moved along a respective first transverse axis (R) perpendicular to the work axis (A) by a corresponding hydraulic actuator (15). A pressurized oil hydraulic system (100) is provided that is associated with the machine, which comprises an oil storage tank (200), a circulation pump (101) connected to the storage tank (200), at least two accumulators (106, 107) connected to the hydraulic actuators (15), each which having at the outlet an interception valve (108, 109) for directing the pressurized oil flow towards the hydraulic actuators (15) in order to allow their movement along the transverse axis R and their rolling action. The invention also relates to a rolling process for forming impressions on cylindrical bodies by means of such a roller machine.