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Energy saving and performance enhancement of hydraulic fineblanking press assisted with controllable hydraulic accumulator for sustainability

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Abstract

In this study, a novel double-stage hydraulic system incorporating a hydraulic controllable accumulator (HCA) was proposed to simultaneously improve the energy and working efficiency of the hydraulic fineblanking press. Within this system, an innovative controller was proposed to orchestrate the HCA’s operations, allowing it to adeptly adapt to abrupt pressure fluctuations and the energy demands from the external load. Within this study, a meticulous analysis was conducted to assess the energy demands of the fineblanking process and the function requirements of the hydraulic system. Subsequently, the energy consumption model based on the energy conservation law was established to analyze the supply–demand relationship of each stage and the energy conversion characteristic of capacitive energy, inertial energy, and resistive energy, thereby calculating these key parameters of the HCA. Then, an accurate simulation model was meticulously established and ultimately validated by the 1000-ton hydraulic fineblanking press, enabling a comprehensive assessment of the system’s working performance and energy consumption characteristics. The simulation and experimental results showed that within this proposed system, the main cylinder circuit accounted for a big part of energy consumption, three times higher than that of the fast cylinder circuit. In the fast cylinder circuit, both resistive and capacitive energy were prominent, whereas in the main cylinder circuit, capacitive energy took precedence. Compared to the traditional system, the proposed system performed better with lower system pressure fluctuation and higher working efficiency increased by 10%. Moreover, the energy efficiency of the proposed system reached 45.9%, 20.35% higher than that of the traditional system, resulting in a reduction in energy consumption of 169.4 kJ per duty cycle.

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Abbreviations

FC:

Fast-closing stage

AD:

Anomaly detection stage

FB:

Fineblanking stage

UP:

Pressure unloading stage

FO:

Fast-opening stage

PID:

Proportion integration differentiation

A j :

Contact area between the piston and the cylinder block (mm2)

c :

Flow coefficient of cartridge valves (Null)

C ic :

Cylinder leakage coefficient (W/bar2)

C s :

Pump leakage flow rate (Null)

d c :

Valves spool diameter (mm)

B c :

Friction coefficient (N/m2)

k 1, k 2 :

Constant parameters of motor (Null)

q d :

Overflow flow (m3/s)

l :

Pipe length (mm)

n p :

Pump rotational speed (r/min)

P a :

Valve input pressure (Pa)

P b :

Valve output pressure (Pa)

p e :

Motor power loss (W)

p f :

Pipe local loss (W)

p j :

Power loss along in parallel pipe (W)

p n :

Motor nominal power (W)

l :

Pipe length (mm)

p s :

Overflow pressure

p u :

SAM output power (W)

T out :

Pump output torque (Nm)

T fic :

Pump internal friction torque (Nm)

v t :

Oil velocity in pipe (m/s)

x 0 :

Spool displacement (mm)

p u :

SAM output power (W)

L 1 :

FC stroke

L 2 :

AD stroke

L 3 :

Whole stroke of the slider

x 1 :

Target displacement signal

η v :

Pump volumetric efficiency (Null)

η m :

Pump mechanical efficiency (Null)

μ :

Dynamic viscosity of the oil (Ns/m2)

ρ :

Oil density (kg/m3)

α :

Valves spool cone angle (°)

λ :

Resistance coefficient

Δq :

Pump leakage flow (m3/s)

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Acknowledgements

The authors would like to thank Huangshi Huali Metal Forming Machine Tool Co., Ltd, for providing the technology parameters. The authors also thank the Fundamental Research Funds for the Central Universities WUT:501 2019III117CG, 111 Project (B17034), Innovative Research Team Development Program of 502 Ministry of Education of China (No. IRT_17R83), for the financial support given to this research.

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Author notes

  1. The authors Zhicheng Xu and Lin Hua contributed equally to this work.

Authors and Affiliations

  1. Hubei Key Laboratory of Advanced Technology of Automotive Components, Wuhan University of Technology, Wuhan, 430070, China

    Zhicheng Xu, Lin Hua & Yanxiong Liu

  2. Hubei Collaborative Innovation Center for Automotive Components Technology, Wuhan University of Technology, Wuhan, 430070, China

    Zhicheng Xu, Lin Hua & Yanxiong Liu

  3. School of Materials Science and Engineering, Wuhan University of Technology, Wuhan, 430070, China

    Zhicheng Xu

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  1. Zhicheng Xu
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Contributions

Zhicheng Xu: methodology, characterizations, and writing first draft. Lin Hua: review and editing and financial support. Yanxiong Liu: supervision and final draft. All authors have read and agreed to publish the manuscript.

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Correspondence to Zhicheng Xu or Yanxiong Liu.

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Xu, Z., Hua, L. & Liu, Y. Energy saving and performance enhancement of hydraulic fineblanking press assisted with controllable hydraulic accumulator for sustainability. Int J Adv Manuf Technol 131, 1119–1136 (2024). https://doi.org/10.1007/s00170-024-13082-0

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