Machine Press Hydraulic Bypass for Energy and Safety
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Machine presses with hermetically sealed hydraulic drive units face challenges in maintaining operating safety and efficiency, particularly during stoppage times, due to the risk of leaks and tilting of the upper die, and require energy consumption for maintaining the upper die in its lowered position.
Innovation Solution
The machine press incorporates a bypass system with controlled stop valves to switch between working and idle modes, allowing the upper die to be lowered without hydraulic activation, reducing the risk of leaks and energy consumption, and calibrates the hydraulic drive units to ensure synchronized operation and optimal pressure conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the upper die is kept in the maximally raised position by constant pressurization of the raising working chamber, then the machine press is ready for immediate operation, but energy is continuously consumed and the risk of leaks increases during stoppage times
Solution Approach 1:
The system dynamically switches between two operational modes (working mode and idle mode) based on operational needs. In working mode, the upper die is pressurized and ready for operation. In idle mode, the system releases pressure and lowers the upper die to minimize energy consumption and leak risks. This dynamic adaptation resolves the contradiction between maintaining readiness (safety) and reducing energy use during stoppages.
Solution Approach 2:
The system changes the pressure parameter in the hydraulic system between working and idle modes. During idle mode, pressure is reduced or released, allowing the upper die to be lowered without continuous pressurization. This parameter change enables the system to maintain operational capability while reducing energy consumption and leak risks during stoppage periods.
2Speed
If the upper die is kept in the maximally raised position during stoppage times, then the machine press can quickly resume operation, but the upper die may tilt due to unilateral or uneven leaks
Solution Approach 1:
The system uses dynamic mode switching to alter the stability conditions during stoppage times. In idle mode, the upper die is lowered to a stable position on mechanical stops, eliminating tilt risks. When operation needs to resume, the system quickly transitions back to working mode, restoring pressure and raising the upper die. This dynamic approach maintains both stability during stoppages and quick response capability.
Solution Approach 2:
The system prepares for potential leaks by having a pre-planned idle mode where the upper die is lowered to mechanical stops. This beforehand preparation ensures that even if leaks occur during stoppage times, the upper die remains stable and cannot tilt, as it is supported by mechanical stops rather than relying solely on hydraulic pressure.
3Reliability
If a bypass is provided parallel to the pressure transformer with stop valves, then the system can switch between working and idle modes to reduce energy consumption and improve safety, but the device complexity increases
Solution Approach 1:
The hydraulic control system is segmented into distinct functional components: the pressure transformer for working mode, and a bypass circuit with stop valves for idle mode. This segmentation allows independent control of each mode, enabling the system to switch between them. The added complexity is localized to the bypass circuit, while the main pressure transformer remains unchanged, making the overall system manageable.
Solution Approach 2:
The bypass circuit with stop valves acts as an intermediary mechanism that enables mode switching without fundamentally redesigning the entire hydraulic system. The stop valves serve as mediators that can open or close flow paths to transition between working and idle modes. This intermediary approach adds controlled complexity only where needed, rather than requiring complete system redesign.
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 enhances operating safety by preventing tilting and reducing energy consumption, while maintaining optimal hydraulic conditions for efficient operation, allowing for precise control of pressure and fluid management, thus improving the overall performance and efficiency of the machine press.
Implementation Method 1
one and the same pressure accumulator on the one hand (directly) pressurizes the raising working chamber and on the other hand—via a pressure transformer—supplies an initial pressure in the hydraulic system
Implementation Method 2
via a pressure transformer—supplies an initial pressure in the hydraulic system
Implementation Method 3
the upper die—via the pressure accumulator connected to the raising working chamber and pressurizing it constantly—is initially preloaded in the direction of the upper dead point
Implementation Method 4
a bypass having a first stop valve, which can be controlled by the control unit and in its blocking position blocks at least the flow direction from the high-pressure side of the pressure transformer to its low-pressure side
Data Source
AI summary
A machine press is provided in which at least one hermetically sealed hydraulic drive unit is switchable from a working mode, in which a base pressure above ambient pressure is continually exceeded, into a rest mode. To this end, in parallel with a pressure converter, to the high-pressure side of which a pressure store and a raising working chamber of a cylinder piston unit are connected, a bypass is provided, having a first blocking valve that is controllable by a control unit and, in its blocking position, blocks the through-flow direction from the high-pressure side of the pressure converter to the low-pressure side. Furthermore, the low-pressure side is connectable to a lowering working chamber via a second blocking valve controllable by the control unit. The pressure output of the hydraulic unit is connectable to the raising working chamber via a third blocking valve controllable by the control unit.