Skip to main content
SpringerLink
Log in

Displacement and dual-pressure compound control for fast forging hydraulic system

  • Published:
Journal of Mechanical Science and Technology Aims and scope Submit manuscript

Abstract

The poor energy efficiency is a big issue in the conventional electro-hydraulic proportional valve controlled fast forging system due to the huge throttling losses and overflow losses. Aimed to address this problem, a new compound control strategy of displacement and dual-pressure was proposed in this study. Firstly, the mathematic model of the main components was built, and the compound control strategy was designed depending on the different working conditions. Then, the overall control system was integrated for both downstroke stage and return-stroke stage. The proposed control strategy was tested and evaluated in a 0.6 MN fast forging press. Results indicated that the input energy was reduced by 50% and energy loss decreased dramatically while control performance was good. Results also show that control performance and energy saving are significantly affected by the variation of △p and p b . Overall, the proposed new control strategy could be used for the fast forging press with high energy efficiency.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. K. Raz, V. Kubec and M. Cechura, Dynamic behavior of the hydraulic press for free forging, Procedia Engineering, 100 (2015) 885–890.

    Article  Google Scholar 

  2. J. Yao and X. D. Kong, Study on process control characteristics of 22MN fast forging hydraulic press, Advanced Materials Research, 201-203 (2011) 2258–2262.

    Article  Google Scholar 

  3. J. Cruz and J. A. Ferreira, Testing and evaluation of control strategies for a prototype hydraulic press, Proc. IMECE’03, 2003 International Mechanical Engineering Congress & Exposition, Washington, USA (2003) 195–202.

    Google Scholar 

  4. X. J. Lu and M. H. Huang, System decomposition based multi-level control for hydraulic press machine, IEEE Trans. on Industrial Electronics, 59 (4) (2012) 1080–1087.

    Article  MathSciNet  Google Scholar 

  5. B. J. Chen, S. H. Huang, J. F. Gao and L Jin, Control strategy for free forging hydraulic press, Journal of Mechanical Engineering, 44 (10) (2008) 304–307.

    Article  Google Scholar 

  6. X. J. Lu and M. H. Huang, Two-level modeling based intelligent integration control for time-varying forging processes, Industrial and Engineering Chemistry Research, 54 (2015) 5690–5696.

    Article  Google Scholar 

  7. Y. C. Li, L. H. Zhang and C. Zhang, Prediction and analysis of forged workpiece’s precision in hydraulic press based on BP neural network and genetic algorithm, Advanced Materials Research, 97-101 (2010) 2598–2602.

    Article  Google Scholar 

  8. V. Alimirzaloo and M. H. Sadeghi, Optimization of the forging of aerofoil blade using the finite element method and fuzzy-Pareto based genetic algorithm, Journal of Mechanical Science and Technology, 26 (6) (2012) 1801–1810.

    Article  Google Scholar 

  9. K. Zhao, Z. F. Liu, S. Y. Yu and X. Y. Li, Analytical energy dissipation in large and medium-sized hydraulic press, Journal of Cleaner Production, 1 (8) (2014) 1–7.

    Google Scholar 

  10. J. Yao, X. D. Kong, L. X. Quan and Y. J. Gao, Study on modeling simulation and test of fast forging hydraulic press using accumulator, China Mechanical Engineering, 20 (2) (2009) 241–244.

    Google Scholar 

  11. M. Q. Dai, S. D. Zhao and X. M. Yuan, The application study of accumulator used in hydraulic system 20MN fast forging machine, International Conference on Information Engineering for Mechanics and Materials, Shanghai, China (2011) 870–874.

    Google Scholar 

  12. H. B. Zheng and Y. S. Sun, Research on pump-controlled servo hydraulic press and its energy consumption experiments, Advanced Materials Research, 988 (2014) 590–596.

    Article  Google Scholar 

  13. J. M. Zheng, S. D. Zhao and S. G. Wei, Fuzzy iterative learning control of electro-hydraulic servo system for SRM direct-drive volume control hydraulic press, Journal of Central South University of Technology, 17 (2) (2010) 316–322.

    Article  Google Scholar 

  14. Y. G. Peng and J. W. Wang, Model predictive control of servo motor driven constant pump hydraulic system in injection molding process based on neurodynamic optimization, Journal of Zhejiang University-Science A, 15 (2) (2014) 139–146.

    Article  Google Scholar 

  15. F. Huang and Y. M. Xu, Modeling and simulation of pressure-flow compound control electro-hydraulic system power source, Machine Tool & Hydraulics, 39 (11) (2011) 125–130.

    Google Scholar 

  16. S. H. Cho and P. Noskievič, Position tracking control with load-sensing for energy-saving valve-controlled cylinder system, Journal of Mechanical Science and Technology, 26 (2) (2012) 617–625.

    Article  Google Scholar 

  17. B. Eriksson and J. O. Palmberg, Individual metering fluid power systems: challenges and opportunities, Journal of Systems and Control Engineering, 225 (3) (2011) 196–211.

    Google Scholar 

  18. S. Liu and B. Yao, Coordinate control of energy saving programmable valves, IEEE Transactions on Control Systems Technology, 16 (1) (2008) 34–35.

    Article  Google Scholar 

  19. K. Janne and M. Jouni, An energy-efficient high performance motion control of a hydraulic crane applying virtual decomposition control, IEEE International Conference on Intelligent Robots and Systems, Tokyo, Japan (2013) 4426–4433.

    Google Scholar 

  20. B. Yao and D. Chris, Energy-saving adaptive robust motion control of single-rod hydraulic cylinders with programmable valves, Proceedings of the American Control Conference, Anchorage, AK, USA (2002) 4819–4824.

    Google Scholar 

  21. B. Yao and S. Liu. Energy-saving control of hydraulic systems with novel programmable valves, Proceedings of the World Congress on Intelligent Control and Automation (WCICA) Shanghai, China (2002) 3219–3223.

    Google Scholar 

  22. B. Xu, R. Q. Ding and J. H. Ding, Experiment research on individual metering systems of mobile machinery based on coordinate control of pump and valves, Journal of Zhejiang University (Engineering Science), 49 (2) (2015) 93–101.

    Google Scholar 

  23. A. H. Hansen, H. C. Pedersen, T. O. Andersen and L. Wachmann, Design of energy efficient SMISMO-ELS control strategies, Proceedings of 2011 International Conference on Fluid Power and Mechatronics, Beijing, China (2011) 522–527.

    Chapter  Google Scholar 

  24. X. J. Lu and M. H. Huang, Novel multi-level modeling method for complex forging processes on hydraulic press machines, International Journal of Advanced Manufacturing Technology, 79 (2015) 1869–1880.

    Article  Google Scholar 

  25. J. Yao, B. Li, Y. Song, X. D. Kong and Z. Zhang, Study on Hydraulic Press Fast Forging Energy-saving Control System Based on Variable Frequency Adjustment, China Mechanical Engineering, 26 (6) (2015) 749–755.

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. The Laboratory of Heavy Machinery Fluid Power Transmission and Control in Hebei, Yanshan University, Qinhuangdao, 066004, China

    Jing Yao & Xiangdong Kong

  2. National and Local Joint Engineering Center for Advanced Forging Press Forming Technology and Equipment Faculty of Engineering, Yanshan University, Qinhuangdao, 066004, China

    Jing Yao & Xiangdong Kong

  3. Yanshan University, Qinhuangdao, 066004, China

    Jing Yao, Bin Li, Xiangdong Kong & Fang Zhou

Authors
  1. Jing Yao
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Bin Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Xiangdong Kong
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Fang Zhou
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Jing Yao.

Additional information

Jing Yao was born in China. She received the B.S. in mechanical engineering from Yanshan University, Qinhuangdao, China in 2001, and M.S. and Ph.D. degrees in Mechatronics Engineering from Yanshan University in 2004 and 2009, respectively. She is currently an associate professor of Mechatronics Engineering, Yanshan University. Her research interests include electro-hydraulic servo control and heavy machinery fluid transmission and control.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Yao, J., Li, B., Kong, X. et al. Displacement and dual-pressure compound control for fast forging hydraulic system. J Mech Sci Technol 30, 353–363 (2016). https://doi.org/10.1007/s12206-015-1240-5

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12206-015-1240-5

Keywords

Search

Navigation