Research On Energy Transfer And Utilization Mechanism And Energy-saving Of Automatic Hydraulic Fine Blanking Press

Due to environmental degradation and resource shortage,low-carbon green manufacturing such as fine-blanking technology has become the important trends of industrial manufacturing,especially in high-end manufacturing.Fine-blanking technology is an advanced stamping method based on ordinary stamping technology for forming medium steel plate.Therefore,it is widely applied in the automotive,aerospace,and military industries.Fine-blanking press is the most important equipment for fine-blanking technology.However,the energy utilization efficiency of the fine-blanking press is pretty low,resulting in an enormous waste of electric energy.To improve the energy utilization efficiency of the fine-blanking press and reduce carbon emissions,this thesis took 10,000 k N full-automatic hydraulic fine-blanking press as the research object.Through experimental and simulation methods,the energy transfer,conversion,and dissipation of the hydraulic system were explored.A new type of valve-pump combined controlled hydraulic system and a novel controllable accumulator were proposed.Additionally,an intelligent energy online platform for monitoring the hydraulic system was established.The research content includes the following aspects:（1）Building the method of fine-blanking press hydraulic system design,energy transfer,conversion,and dissipation analysis and energy consumption optimization and proposing the high-low pressure valve controlled double circuit hydraulic system.The load characteristics of the fine-blanking press in each stage were in-depth studied from both qualitative and quantitative levels.The requirements of system function and design principles were illuminated,and the parameters of the key components were calculated.The high-low pressure double-circuits were proposed.The energy dissipation mathematical model and simulation model of different types of hydraulic components were established.The energy simulation model of the high-low pressure valve controlled double circuit hydraulic system was built to reveal the energy dissipation characteristics under different loads.In addition,the key parameters of the main hydraulic system were optimized.Experiment and simulation results showed that the energy efficiency of the hydraulic system was only 15%.After optimizing the system overflow pressure,the total input energy dropped sharply,and energy utilization efficiency under low-load conditions increased by 8%to 10%.（2）To overcome the disadvantages of traditional accumulators,a novel controllable hydraulic accumulator was proposed.The volume ratio（r₀）of the controllable accumulator was 0.5,which was co MParable with traditional accumulators.For the energy device,the effective working volume（ΔV）,precharge pressure（P₀’）,storage energy（E_a）,and energy storage density（E_ρ）were increased by50%,76.4%,50%,and 50%respectively.The simulation results showed that this novel accumulator can enable the total input energy decreased by 158.1 k J and the energy efficiency improved by 16.2%.（3）To decrease the energy dissipation of the hydraulic system,a novel valve-pump combined hydraulic system was proposed.Based on the energy conservation law,the key parameters of the components were calculated,and the AMEsim simulation model and experimental platform were established for verifying the feasibility of the proposed system.The results showed that the novel system had better performance and energy-saving characteristics than the high-low pressure valve controlled double circuit hydraulic system.Compared with the traditional system,the average energy efficiency and work efficiency of the novel system were enhanced by20%and 14.7%,respectively.（4）To monitor the working status of the fine-blanking press and distribution of component energy consumption,this thesis used Deep Learning technology to develop a real-time energy monitoring platform for the hydraulic system.According to the components’functions,all components were divided into energy supply components,auxiliary components,control components and actuators.Furthermore,the minimum energy unit of each stage was created,and the features of energy consumption were extracted through the simulation model.A 1D-CNN model was established to identify the working stage of the fine-blanking machine and predict the energy dissipation of each minimum energy unit.The results showed that the1D-CNN model can better identify the power difference of each stage,and the recognition accuracy can reach 98.4%.The prediction accuracy of the minimum energy unit of each stage can reach 90%.This research revealed the basic laws of energy transfer,conversion and dissipation of complex hydraulic systems,and explored the root causes of the low efficiency of hydraulic systems.Innovations were made from the component and system sub-levels to improve the energy utilization rate and working performance of the hydraulic system of a fine blanking press.Furthermore,a real-time monitoring strategy for the complex hydraulic system was proposed.The output can be applied not only on the fine-blanking machine,but also on the ordinary stamping equipment,offering guiding significance for energy-saving and emission reduction in the metal stamping industry.