Hydraulic Press and Die Cushion Load-Canceling Architecture
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional press systems driven by servo motors have high costs and energy inefficiencies due to the separation of main drive mechanisms for press and die cushion operations, leading to increased servo motor capacity and power requirements.
Innovation Solution
A press system with integrated hydraulic cylinders and valves that allow communication between pressure generation chambers to cancel die cushion loads, reducing the overall servo motor capacity and enhancing energy efficiency by only applying forming loads to the slide.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If servo motors are used to drive both the press machine and die cushion apparatus, then the press system achieves precise control and automation, but the servo motor capacity and power requirements increase significantly
Solution Approach 1:
The patent merges the drive mechanisms of the press machine and die cushion apparatus by using a single servo motor (106-1 to 106-4) to drive hydraulic pumps/motors that control both the slide (110) and cushion pad (128). This integration allows one servo motor to replace what would traditionally require separate motors, reducing total power requirements while maintaining precise control of both operations.
Solution Approach 2:
The hydraulic pumps/motors (105-1 to 105-4) serve multiple functions: they drive the slide for press operations and simultaneously control the die cushion apparatus. The same hydraulic system that powers the main press mechanism also powers the cushioning function, making the drive system universal and reducing the need for dedicated high-capacity motors for each function.
2Reliability
If separate drive mechanisms are used for press and die cushion operations, then each function can be optimized independently, but the overall system complexity and cost increase
Solution Approach 1:
The patent combines the drive mechanisms into a unified system where a single servo motor controls hydraulic pumps that serve both press and die cushion functions. This merging reduces the number of independent drive systems from two to one, simplifying the overall system architecture while maintaining the ability to independently control each function through hydraulic circuitry.
Solution Approach 2:
The patent uses hydraulic systems to transmit and distribute power from the single servo motor to both the press slide and die cushion apparatus. The hydraulic pumps/motors and cylinders create a flexible power distribution network that allows independent control of each function while sharing a common drive source, thereby reducing mechanical complexity.
3Ease of operation
If a die cushion apparatus with servo motor is mounted on a servo press, then precise die cushion control is achieved, but the control panel size and power receiving capacity increase
Solution Approach 1:
The servo motor (106-1 to 106-4) performs dual functions: controlling both the press slide movement and the die cushion apparatus operation. By making the servo motor universal, the control system and power supply need only be sized for one motor rather than two separate motors, reducing control panel size and power receiving capacity while maintaining precise control of both functions.
Solution Approach 2:
The control systems for the press and die cushion apparatus are merged into a single servo motor control architecture. The servo motor receives unified control signals that coordinate both press operation and die cushioning, eliminating the need for separate control panels and power supplies that would be required for independent servo motors on each system.
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 significantly reduces servo motor capacity by 60% and improves energy efficiency by allowing the press system to handle forming loads independently of die cushion loads, thereby lowering costs and improving operational efficiency.
Implementation Method 1
a first hydraulic cylinder (130) configured to support a cushion pad (128) and apply a die cushion load to the cushion pad when a slide (110) of the press machine (100-1, 100-2) descends
Implementation Method 2
a second hydraulic cylinder (137) configured to apply a part of a press load to the slide (110) when the slide (110) descends
Implementation Method 3
a piping (155) configured to connect between a first pressure generation chamber (130b) which is provided to the first hydraulic cylinder (130) and configured to generate the die cushion load, and a second pressure generation chamber (137b) which is provided to the second hydraulic cylinder (137) and configured to generate the part of the press load
Data Source
AI summary
A press system providing excellent energy efficiency for a whole press system and capable of achieving low prices is provided. A die cushion apparatus constituting a press system supports a cushion pad, includes a hydraulic cylinder which generates a die cushion load on the cushion pad when a slide of a press machine descends, the press machine includes a hydraulic cylinder which generates part of a press load on the slide when the slide descends. The pressure generation chamber of the hydraulic cylinder for generating a die cushion load and the pressure generation chamber of the hydraulic cylinder for generating part of the press load can communicate with each other via pipes and a first logic valve for a period during which the die cushion load acts.