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Research Papers

Improving the Energy Efficiency of a Hydraulic Press Via Variable-Speed Variable-Displacement Pump Unit

[+] Author and Article Information
Haihong Huang

School of Mechanical Engineering,
Hefei University of Technology,
Hefei 230009, Anhui, China
e-mail: huanghaihong@hfut.edu.cn

Rui Jin

School of Mechanical Engineering,
Hefei University of Technology,
Hefei 230009, Anhui, China
e-mail: hfur_jr@live.com

Lei Li

School of Mechanical Engineering,
Hefei University of Technology,
Hefei 230009, Anhui, China
e-mail: hfut_lilei@hotmail.com

Zhifeng Liu

School of Mechanical Engineering,
Hefei University of Technology,
Hefei 230009, Anhui, China
e-mail: zhfliuhfut@126.com

1Corresponding author.

Contributed by the Dynamic Systems Division of ASME for publication in the JOURNAL OF DYNAMIC SYSTEMS, MEASUREMENT,AND CONTROL. Manuscript received November 17, 2016; final manuscript received May 17, 2018; published online June 18, 2018. Editor: Joseph Beaman.

J. Dyn. Sys., Meas., Control 140(11), 111006 (Jun 18, 2018) (10 pages) Paper No: DS-16-1561; doi: 10.1115/1.4040325 History: Received November 17, 2016; Revised May 17, 2018

Hydraulic presses are widely applied in various forming processes to manufacture products with complex shapes, however, they are energy-intensive. In order to lower the energy consumption, a variable-speed variable-displacement pump unit (SVVDP) was developed for hydraulic presses, where the flow rate required by the press in a forming process can be realized by changing the motor rotating speed and the pump displacement simultaneously. A theoretical model was built to reveal the energy dissipation behavior of the drive unit, which shows that the energy efficiency of the drive unit can be optimized by varying the rotating speed of the motor under a variety of load conditions. An experimental platform with a SVVDP was established to find the optimum rotating speed and the corresponding displacement in different load conditions, and experimental results verified the improved energy efficiency of the SVVDP compared with that of the commonly used single variable drive unit. By employing the strategy that the determined optimum rotating speeds in different load conditions were preset as recommended values for the drive unit working in different operations, the proposed drive unit was applied to a press completing a forming process and the results indicate significant energy saving potentials.

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Figures

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Fig. 1

Energy conversion of a hydraulic press based on Ref. [1]

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Fig. 2

Power profile of a hydraulic press

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Fig. 3

Schematic of hydraulic press with the SVVDP (V is the displacement of the pump, n is the speed of the motor, X is the position of the slider, F is the force acting on the slider, p is the outlet pressure of the pump, Q is the flow rate of the hydraulic system, and U is the output voltage of the corresponding sensor)

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Fig. 4

Energy flow of the drive unit in SVVDP

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Fig. 5

Schematic of the experimental platform

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Fig. 6

Energy efficiency of the SVVDP varying with the rotating speed with the output flow rates Q at: (a) 20 L/min, (b) 25 L/min, and (c) 30 L/min

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Fig. 7

Energy efficiencies of different drive units varying with the pump outlet pressure with Q at: (a) 20 L/min, (b) 25 L/min, and (c) 30 L/min

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Fig. 8

Schematic of the cells (output pressure and flow rate of the pump)

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Fig. 9

Overview of the control strategy applied to the hydraulic press with the SVVDP (v is the velocity of the slider and the positive value indicates that the slider moves downward, X is the position of the slider, and BPα is the beginning position of the operation α)

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Fig. 10

Displacement of the slider, system pressure profile, system flow rate profile, and operations performed in a forming process

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