The Design Of 630kJ Hammer Blow Energy For On-line Measurement System

Mechanical forging hammer is one of the oldest and the most common mechanical forging equipment, the up and down hammer heads collided in high speed, driven by releasing energy of high pressure gas, is the most practical forging method of all kinds of Metal Forming. The forging hammer blow, 630kJ, is the main large tonnage forging equipment, providing a lot of supplies for aerospace equipment construction in China, but the key components of the hammer, such as rod hammer, hammer head and mold, are destructed frequently, because of long-term strength to forge metal. Meanwhile, the components of the hammer has a high cost from casting to finished products and a long cycle of repairing and processing. High price and tedious process cycle has become a major problem, which puzzle the production department of mechanical forging hammer, extremely. Different forgings need different striking energy, therefore, it’s far from enough to judge the blow force (lift height and hammer blow sound) relying on the experience of blacksmith, too large or too small force both affect the quality of forgings, also adverse to long time running of the equipment and largely reduce the life of the equipment.Controlling the blow energy, strictly, during the forging process is the only way to guarantee the quality of forgings and the normal operation of the equipment. Complete measure striking energy is convenient to master the performance of the device, systematically, and the maintenance after put into operation, reducing the chance of damage to hammer, providing reliable scientific basis for the workers in the forging process, ensuring the quality forgings. In this paper, we design a new type of hammer blow energy automatic acquisition and processing of wireless measurement system under the background of practical engineering, which specific to the harsh environments of the hammer blow’s energy measurement and the poor real-time capability, low precision, complex operations of the traditional methods, composed by the host, the slave and the wireless modules. Using the STM32 processor of embedded ARMv7 and low power,433 M, wireless module SI4432 to built hardware platform, plus a host protection box mounted on the wall, the slave and the acceleration sensor mounted on the hammer, choosing piezoelectric acceleration sensor and charge amplifier to calculate the maximum blow force and the blow energy, then transfers data to the host through the wireless module. The host collects displacement, pressure and other parameters, receiving and processing the data transmitted form salve modules, using RS485 serial communication sent data to the scene LED big screen in real time, providing the scientific basis for the field workers, storing the blow parameters into the PC database.At present, the measurement system has been successfully applied to a production workshop of Aviation Forging & Casting Industry Company. Through field testing, the system has advantages of low power consumption, high accuracy and low cost, plays a good reference for the company to master the hammer blow energy, reduces the chance of damage to the hammer rod, effectively, also by the user praise.