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Energy-Saving Design Method for Hydraulic Press Drive System with Multi Motor-Pumps

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Abstract

Large energy consumption caused by the pump unloading, as well as the low energy efficiency of the motor, is a serious problem for hydraulic presses especially for the press with multi motor-pumps. By analyzing the energy dissipation characteristic of hydraulic press drive system which is composed of several motor-pumps used to provide energy, an energy-saving design method is developed to reduce the energy loss of the drive system. In this method, pumps are selected from the pump set by minimizing the proposed idling index to reduce the energy loss of motor-pumps in the unloading state. The index is defined as the sum of the product of the unloaded flow and the unloaded time for each stage in a working cycle of the hydraulic press. Then, the motors are selected from the motor set to drive the selected pumps correspondingly by ensuring that the load rate of all the motors is within a setting range for high energy efficiency in as many stages as possible. The method was applied to a 2000-ton rapid sheet tension hydraulic press, and results indicate that 26.97% of energy can be saved in a working cycle.

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Abbreviations

P in :

Input power of the drive system

P unloading :

Power loss of the motor-pumps in the unloading state

η i :

Energy efficiency of motor-pump i accessed to hydraulic circuit

η pump(p):

Energy efficiency of pump

β :

Ratio of output power to rated power of a motor

η motor(β):

Energy efficiency of motor

Δp j :

Pressure loss of hydraulic circuit in working stage j

U :

Sum of the product of the unloaded flow and the unloaded time in each stage of the hydraulic press in a working cycle

Zij :

State of motor-pump i in stage j

\(q_{i}^{\rm u}\) :

Unloaded flow of motor-pump i

q k(p j):

Flow of pump k in the pump set when it works at the pressure of pj

a k :

Number of selected pump k

P N i :

Rated power of the selected motor i

q i(p j):

Flow of the selected variable pump i at the pressure of pj

P i(p j):

Output power of selected variable pump i in stage j

η pumpi(p j):

Energy efficiency of selected pump i when its working pressure is pj

η motori(p j):

Energy efficiency of selected motor i in stage j

β i(p j):

Load rate of selected motor i in stage j

E in :

Total energy consumption of the original drive system in a working cycle

\(E_{\text{in}}^{\prime }\) :

Total energy consumption of the designed drive system in a working cycle

E i(p j):

Output power of motor-pump i accessed to hydraulic circuit in stage j

η i(p j):

Energy efficiency of motor-pump i accessed to hydraulic circuit in stage j

n j :

Number of motor-pumps which are in the unloading state in stage j

ΔE :

Energy consumption reduction

\(P_{\text{N}}^{\prime }\) :

Installed power of the designed drive system

η :

Energy efficiency of the original drive system

\(\eta^{\prime }\) :

Energy efficiency of the designed drive system

ERR:

Energy consumption reduction rate

EIR:

Energy efficiency increment rate

PRR:

Installed power reduction rate

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Acknowledgements

The work is financially supported by the National Natural Science Foundation of China under Grant nos. 51722502 and 51635010, the International Cooperation and Exchange of the National Science Foundation of China Grant no. 51561125002.

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Correspondence to Haihong Huang.

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Huang, H., Zou, X., Li, L. et al. Energy-Saving Design Method for Hydraulic Press Drive System with Multi Motor-Pumps. Int. J. of Precis. Eng. and Manuf.-Green Tech. 6, 223–234 (2019). https://doi.org/10.1007/s40684-019-00085-6

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