Research On The Energy Consumption Mechanism And Energy-saving Control Of Fast Forging Hydraulic System In Valve-control Press

Energy-saving is the hot theme in the large environment of global economicdevelopment. The sustainable development of energy is more and more important.Forging hydraulic press is a kind of heavy machine in the industry of machineequipment，and is important symbol for manufacturing industry level of a country.Since the second half of the last century, fast forging press is favored by people becauseof its fast forging velocity and accurate control precision. As a forging machine, fastforging press has considerable energy consumption. The research on energy-savingcharacteristic of hydraulic system in fast forging press is very important, which will bringlarge economic benefit. Energy utilization rate of every part in the system will beimproved through analyzing the energy consumption theory in the hydraulic system, andthen installed power from source will be reduced.In this paper, valve-controlled hydraulic press system was mainly researched,distribution law of system was sought and energy consumption mechanism was analyzedas well. The causes of consumption on each component were proposed from theperspective of power flow. The relationship among consumption, system pressure,forging frequency and controller parameters was summarized.The trend of power flow was stated based on component power bond graph modelsincluding fixed displacement pump, proportional relief overflow valve, accumulator andhydraulic cylinder with load. AMESim model of the22MN fast forging press hydraulicsystem was built, and distribution law of large-tonnage system was sought according tothe model. The universality of that law was verified in the AMESim model of the0.6MNexperimental fast forging press hydraulic system. Pipelines’ energy consumption in thesetwo systems were analyzed, their occupancy rate in the whole power input wasconfirmed.Energy regulation system with double accumulators was presented based on formerresults. Each accumulator was added to master cylinder and return cylinder circuit. Theformer one will supply flow over pump input and latter one recycle and reuse the power, then act as power source. The superiority of energy regulation system over originalvalve-control system was analyzed, and its shortages were listed meanwhile.Both systems of fast forging press hydraulic system and energy regulation systemwith double accumulators were studied, based on existing experiment platform of0.6MNfree forging hydraulic press. Rationality of simulation and experiment results wereverified.