CN104785568A - Hydraulic system modeling and energy consumption analysis method of extruder in extrusion process - Google Patents
Hydraulic system modeling and energy consumption analysis method of extruder in extrusion process Download PDFInfo
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Abstract
The invention discloses a hydraulic system modeling and energy consumption analysis method of an extruder in the extrusion process. Aiming at the problem of severe energy consumption loss in the extrusion process, the energy flow direction, the energy conversion type and energy consumption of the hydraulic system of the extruder are analyzed by a technical means by taking an 10MN aluminum extruder as a research object, and a corresponding theoretical energy consumption formula is given, thereby facilitating to summarizing the key element of consumed energy and enabling the energy conservation and optimization of the extruder to be relatively targeted.
Description
Technical field
The invention belongs to energy consumption analysis and the cost control technique field of extruder, particularly relate to a kind of extruder extrusion process hydraulic system modeling and energy consumption analysis method.
Background technology
In recent years, along with the development of aluminium section bar industrial technology and the needs of energy-saving and emission-reduction, to the energy consumption of extruder and the control overflow of product cost more and more higher.
Extruder is as equipment crucial on extrusion process production line, and its energy loss is serious, and extruding efficiency is low, and the operating efficiency of an extrusion cycle is about 60%, and the Conversion of Energy of its loss is heat energy.Wherein, confessed extruder energy consumption is mainly the squeeze stage, and this phase duration is long, power consumption is large, is realize the process that aluminium ingot is squeezed into aluminum products conversion.The dynamical system of extruder is hydraulic transmission mode, and energy loss is the major power loss of hydraulic system.
At present, energy saving research for extruder comprises the reducing energy consumption of extruder appts, the parameter optimization of extrusion process and improves extruded product lumber recovery etc., but deal with problems, first be to locate problem, the current technical method enough accurately that also lacks finds the point to be optimized of extruder fast and accurately.
Summary of the invention
The present invention with 10MN aluminium extruding machine for research object, for the problem that the energy loss of extrusion process is serious, the energy flow being analyzed extruder hydraulic system by technological means is to, power conversion form and energy ezpenditure, and provide corresponding theoretical energy consumption formula, contribute to the key element summing up power consumption, make the energy saving optimizing of extruder more purposive.
The present invention proposes a kind of extruder extrusion process hydraulic system modeling and energy consumption analysis method.
Concrete, for solving the problems of the technologies described above, technical scheme of the present invention is as follows:
Extruder extrusion process hydraulic system modeling and energy consumption analysis method, comprise the steps.
The first step, carries out extrusion process energy consumption analysis, plunger variable pump energy consumption analysis, the energy consumption analysis of inserted valve valve block and squeeze cylinder energy consumption analysis.
Extrusion process energy consumption analysis: observe and energy conversion, element that energy loss is relevant, comprise plunger variable pump, inserted valve, master cylinder, according to input, the output energy consumption relation of element, sets up the power balance equation of system: P
p=η
pp
pi=P
c+ P
v(1); Wherein, P
pi, P
p, η
prepresent the input power of hydraulic pump, power output and efficiency respectively, P
cfor the power output of master cylinder 1, P
vfor the power loss of inserted valve valve block.
Plunger variable pump energy consumption analysis: difference form of leaking is set as follows: the secondary leakage loss q of pump plunger
pp, Slipper coupling leakage loss q
ps, Port Plate Pair leakage loss q
pv, volume compression losses q
pc; In addition, by tripartite for mechanical efficiency loss: the Coulomb friction torque loss T that between pump inner part, relative motion causes
ps, bearing element fricative moment loss T
pr; The torque loss T that pump inner fluid viscous damping causes
pv.
The energy consumption relation of plunger variable pump is set as follows: q
pa=q
pt-Δ q
p=q
pt-(q
pp+ q
ps+ q
pv+ q
pc), T
pi=T
pa+ Δ T
p=T
pa+ T
ps+ T
pr+ T
pv.
The power loss formula of plunger variable pump: Δ P
p=P
pi-P
p=2 π nT
pi-pq
pa; Wherein, q
pa, q
ptactual flow and the theoretical delivery of hydraulic pressure respectively, T
pi, T
pabe respectively motor supply torque and the input torque of hydraulic pressure.
The power loss of inserted valve valve block: the power loss of inserted valve shows as local pressure loss, when fluid enters valve port, diminish rapidly at the area of passage at spool place, form pressure reduction, consumed energy, wherein pressure reduction is relevant with inlet pressure with the opening degree of valve, and the power loss caused because of pressure reduction can represent with following formula: P
v=Δ p
aq
vA; Wherein, Δ p
afor valve port pressure reduction, q
vAfor flowing through the flow of primary valve.
Squeeze cylinder energy consumption analysis: the power loss Δ P of squeeze cylinder
cthere is the mechanical friction loss P between piston rod and piston cylinder
cf, because of cylinder internal leakage formed volumetric loss P
ckand the kinetic energy losses of potential energy P that piston rod movement causes
cr, the power output of squeeze cylinder is P
co, obtain the power balance equation of squeeze cylinder: P
c=P
co+ Δ P
c=P
co+ P
cf+ P
ck+ P
cr.
Second step: set up Simulation Model.
Extrusion process hydraulic system modeling emulates: the hydraulic control system model arranging extrusion process.
Plunger variable pump model is set up: the pump housing is oblique tray type axial plunger piston variable pump, comprises valve plate, plunger cavity volume, swash plate plunger connector and swash plate controller three part; Wherein, for valve plate arranges four ports, represent oil-in, oil-out, plunger hydraulic fluid port and cylinder body corner respectively, its oil-in, oil-out are connected with the high pressure chest of valve plate, low pressure chamber respectively, and cylinder body rotates one week, and plunger completes an oil suction and oil extraction; Plunger cavity volume is made up of plunger, hydraulic pressure cavity volume and leakage hole, and one end connects plunger hydraulic fluid port, and the other end connects swash plate plunger connector; The power transmission shaft inertia input of swash plate plunger connector connects motor, and when cylinder body rotates, connector can actuation plunger move back and forth, and realizes oil suction and oil extraction function according to output corner; Swash plate controller connects the swash plate inertia input of swash plate plunger connector, can be used for regulating swashplate angle, controls pump delivery.
Consider the volumetric loss of the pump housing, comprise plunger pair to leak, Slipper coupling leaks, consider the compressibility of fluid, volume compression losses can be obtained, the Port Plate Pair of each plunger leaks sum and represents in pump housing exit, the mechanical loss of the pump housing is represented by the rotary load torque model with damping, the Parametric Representation of variable pump is as follows: plunger radial position 0.04m, diameter of plunger 28mm, plunger number 9null, diameter of plunger gap 0.01mm, plunger, cylinder body contact length 68.4mm, system pressure 400null, maximum swashplate angle 20degree, pressure-control valve diameter 6mm, Slipper coupling flow leaks 5.6e-2*dpL/min, Port Plate Pair flow leaks 1e-2*dpL/min, Coulomb friction moment loss 7mm, moment of rolling friction loss 3mm, cylinder body rotary inertia 0.02Kgm
2, rotating speed 2100rev/min.
Squeeze cylinder model is set up: set up squeeze cylinder model, consider the mechanical friction between piston rod and piston cylinder respectively, the internal leakage of auxiliary cylinder, the kinetic energy potential energy of piston rod movement and load, the parameter arranging each element is as follows: master cylinder: piston diameter 730mm, diameter of piston rod 730mm, dead-center position 150mm, dead volume 50000cm
3; Auxiliary cylinder: piston diameter 200mm, diameter of piston rod 150mm, dead-center position 30mm, dead volume 1000cm
3, reveal module gap diameter 0.1mm, reveal module gap length 100mm; Pressure ram: gross mass 5x10
6kg; Load is wherein obtained by collection in worksite data.
Inserted valve model is set up: inserted valve comprises valve body and valve seat, and consider the local pressure loss of valve, each component parameters information is as follows: valve latus rectum 40mm, area ratio 14.3:1null, valve port diameter 38.5mm, spool quality 0.4kg, spool-10 ~ 10m, spring rate 1N/mm, pretightning force 1N.
3rd step: carry out simulation results show.
Simulation results show: arranging simulation time is 69s, the commitment defini interval time is 0.01s, moving model also checks simulation result, obtain the extrusion speed curve of extrusion process, pass through post processing, obtain the power characteristic of each dissipative cell of extrusion process, consider that simulation result and actual result exist error, the energy consumption of further analytical model.
4th step: carry out energy consumption analysis.
Energy consumption analysis: energy consumption analysis is carried out to the dissipative cell of model, analyze its power consumption and power loss, comprise the local pressure loss energy consumption of output energy consumption with loss energy consumption, inlet valve of plunger variable pump, the spill losses energy consumption of relief valve, the output energy consumption of squeeze cylinder and loss energy consumption, and curve map is set up to above-mentioned energy consumption and contrasts, quantize energy distribution.
5th step: carry out energy consumption improvement based on energy consumption analysis.
According to the quantization profile data obtained, carry out specific aim improvement, improve energy consumption efficiency.
Usefulness of the present invention is:
The present invention analyzes the operation principle of extrusion process and hydraulic system energy consumption, set up system simulation model, the correctness of verification model, and obtain the energy consumption curve of extrusion process dissipative cell, quantize energy distribution, contribute to drawing the main energy loss causing extruding efficiency not high, and improve targetedly, the method and simulation result have outstanding theoretical foundation and theory directive significance to extruder energy saving research and optimization.
Accompanying drawing explanation
Fig. 1 is the hydraulic system sketch of aluminium extruding machine extrusion process; Wherein, Reference numeral is as follows: 1-master cylinder, 2-auxiliary cylinder, 3-pressure ram, 4-prefill valve, 5-master cylinder enters valve, 6-relief valve, and 7-master cylinder moves back valve, 8-master cylinder oil inlet and oil return valve, 9-sequence valve, 10-master cylinder returns fuel tap, 11-threephase asynchronous machine, 12-plunger variable pump, 13-safety valve;
Fig. 2 is the energy flow graph of the hydraulic process of aluminium extruding machine;
Fig. 3 is extrusion process Hydraulic System Simulation model;
Fig. 4 is single plunger discharge model; Wherein, 20-Port Plate Pair leaks, 21-valve plate, 22-oil-in, 23-oil-out, 24-plunger hydraulic fluid port, 25-plunger cavity volume, 26-swash plate plunger connector, 27-swash plate controller, the secondary leakage hole of 28-, 29-plunger, 30-hydraulic pressure cavity volume;
Fig. 5 is emulation and the extrusion speed comparison diagram in reality;
Fig. 6 is that emulation inputs energy consumption comparison figure with the motor in reality;
Fig. 7 is the output energy consumption figure in energy consumption analysis;
Fig. 8 is the energy loss figure in energy consumption analysis.
Detailed description of the invention
Accompanying drawing, only for exemplary illustration, can not be interpreted as limitation of the present invention.
To those skilled in the art, in accompanying drawing, some known features and explanation thereof may be omitted is understandable.
Below in conjunction with the Figure of description in the present invention, be clearly and completely described the technical scheme in invention, obviously, described embodiment is only the present invention's part embodiment, instead of whole embodiments.Based on the embodiment in the present invention, those of ordinary skill in the art, not making the every other embodiment obtained under creative work prerequisite, belong to the scope of protection of the invention.
The Hydraulic System Principle sketch of extrusion process as shown in Figure 1, squeeze cylinder is made up of two auxiliary cylinders 2 and a master cylinder 1, for asymmetry piston formula structure, each piston-rod end is fixed and is connected pressure ram 3, the major function of auxiliary cylinder 2 has been the actions that move forward and backward of master cylinder 1, and master cylinder 1 is responsible for main extruding forward motion, promotion pressure ram 3 enters recipient and carries out extruding work.The oil circuit of master cylinder 1 and auxiliary cylinder 2 can be controlled by two-way plug-in valve, realize various operating mode.
Extrusion process refers to extruding advancement stage; need to open master cylinder and enter valve 5, sequence valve 9 and master cylinder oil inlet and oil return valve 8, before extruding, master cylinder 1 is by the first topping up of prefill valve 4; during extruding work, relief valve 6 can limit the maximum extrusion pressure in extrusion process, realizes overload protection.Power section, by threephase asynchronous machine 11 actuation plunger variable pump 12, export high pressure liquid power, and electric proportional control mode can control the swashplate angle of plunger variable pump 12, regulates its discharge capacity, realizes the speeds control of extrusion process.
The energy flow of hydraulic process is to as shown in Figure 2.The hydraulic system of extruder comprises dynamical element, executive component, control and regulation element, auxiliary element, driving medium etc., and the functional realiey of each link is along with the consumption of energy.
In extrusion process, hydraulic system has three Conversion of Energies: electric energy conversion is mechanical energy by 1, first motor energising; 2, then by hitch bar, drive hydraulic pump running that mechanical energy is converted to hydraulic energy, export hydraulic oil; 3, hydraulic energy transfer is that mechanical energy carries out extruding work by last extrusion oil cylinder.
Conversion between multi-form energy is inevitable along with energy loss, mainly comprises mechanical friction loss, volumetric loss, spill losses, local pressure loss, kinetic energy losses of potential energy etc., and the loss of this part is transformed into heat energy, oil liquid temperature is raised.
Extrusion process energy consumption analysis: in the Hydraulic Power Transmission System of extrusion process, primary part observation and energy conversion, the element that energy loss is relevant, comprise plunger variable pump 12, inserted valve, master cylinder 1 etc., and according to the input of element, export energy consumption relation, the power balance equation of system can be set up:
P
p=η
pp
pi=P
c+ P
v(1); Wherein, P
pi, P
p, η
prepresent the input power of hydraulic pump, power output and efficiency respectively, P
cfor the power output of master cylinder 1, P
vfor the power loss of inserted valve valve block.
Plunger variable pump 12 energy consumption analysis: the gross efficiency of plunger variable pump 12 mainly comprises volumetric efficiency and mechanical efficiency.Volumetric efficiency is because the high pressure chest oil liquid leakage of hydraulic pump in the course of work is in low pressure chamber, and main leakage form has the secondary leakage loss q of pump plunger
pp, Slipper coupling leakage loss q
ps, Port Plate Pair leakage loss q
pv, volume compression losses q
pc.Mechanical efficiency main manifestations is the loss of three parts: one is the Coulomb friction torque loss T because relative motion between pump inner part causes
ps, comprise sliding friction torque etc. between Port Plate Pair sliding friction torque, Slipper coupling sliding friction torque, typed ball bearing pair; Two is because of bearing element fricative moment loss T
pr; Three is the torque loss T because pump inner fluid viscous damping causes
pv.
The energy consumption relation of plunger variable pump is as follows: q
pa=q
pt-Δ q
p=q
pt-(q
pp+ q
ps+ q
pv+ q
pc), T
pi=T
pa+ Δ T
p=T
pa+ T
ps+ T
pr+ T
pv(3).
The power loss Δ P of plunger variable pump
pformula: Δ P
p=P
pi-P
p=2 π nT
pi-pq
pa; Wherein, q
pa, q
ptactual flow and the theoretical delivery of hydraulic pressure respectively, T
pi, T
pabe respectively motor supply torque and the input torque of hydraulic pressure.
The power loss of inserted valve valve block: inserted valve is by the relative movement between regulating spool and valve pocket, the actual internal area changing valve port controls the fluid flow direction of working connection, power loss main manifestations is local pressure loss, when fluid enters valve port, diminish rapidly at the area of passage at spool place, form pressure reduction, consumed energy.Pressure reduction is relevant with inlet pressure with the opening degree of valve, because of the power loss P that pressure reduction causes
vavailable following formula represents: P
v=Δ p
aq
vA; Wherein, Δ p
afor valve port pressure reduction, q
vAfor flowing through the flow of primary valve.
Squeeze cylinder energy consumption analysis: squeeze cylinder can realize the reciprocating motion of the advance of mechanism, extruding and retrogressing in extrusion process, and its input parameter is flow and the pressure of fluid, and output parameter is the movement velocity and power etc. of mechanism
[.During extruding work, hydraulic oil enters extrusion oil cylinder rodless cavity and promotes piston, overcomes the acting of Metal Deformation stress, its power loss Δ P
cmainly contain the mechanical friction loss P between piston rod and piston cylinder
cf, because of cylinder internal leakage formed volumetric loss P
ckand the kinetic energy losses of potential energy P that piston rod movement causes
cr, the power output of squeeze cylinder is P
co.
The power balance equation of squeeze cylinder: P
c=P
co+ Δ P
c=P
co+ P
cf+ P
ck+ P
cr.
Extrusion process hydraulic system modeling emulates: enter AMESim software environment, the hydraulic pressure storehouse that under draft mode, calling system provides, mechanical storehouse, hydraulic component design storehouse and signal library, build simulation model, energy consumption use for plunger variable pump mentioned above, squeeze cylinder, Cartridge inserted valve integrated block and oil circuit is carried out HCD (driver (HCD (HostControlDriver)) of console controller) with power loss and is designed, and selects the simplest submodel.The hydraulic control system model of extrusion process as shown in Figure 3.
Plunger variable pump model: the pump housing is oblique tray type axial plunger piston variable pump, mainly comprise valve plate 21, plunger cavity volume 25, swash plate plunger connector 26 and swash plate controller 27, single plunger discharge model as shown in Figure 4.Wherein four ports of valve plate 21 represent oil-in 22, oil-out 23, plunger hydraulic fluid port 24 and cylinder body corner respectively, its oil-in 22, oil-out 23 are connected with the high pressure chest of valve plate 21, low pressure chamber respectively, cylinder body rotates one week, and plunger completes an oil suction and oil extraction.Plunger cavity volume 25 is made up of plunger 29, hydraulic pressure cavity volume 30 and secondary leakage hole 28, and plunger cavity volume 25 one end connects plunger hydraulic fluid port 24, and the other end connects swash plate plunger connector 26.The power transmission shaft inertia input of swash plate plunger connector 26 connects motor, and when cylinder body rotates, swash plate plunger connector 26 can actuation plunger move back and forth, and realizes oil suction and oil extraction function according to output corner.Swash plate controller 27 connects the swash plate inertia input of swash plate plunger connector 26, can be used for regulating swashplate angle, controls pump delivery.
Consider the volumetric loss of the pump housing, comprise plunger pair to leak, Slipper coupling leaks, consider the compressibility of fluid, volume compression losses can be obtained, the Port Plate Pair of each plunger leaks sum and represents in pump housing exit, the mechanical loss of the pump housing is represented by the rotary load torque model with damping, the Parametric Representation of variable pump is as follows: plunger radial position 0.04m, diameter of plunger 28mm, plunger number 9null, diameter of plunger gap 0.01mm, plunger, cylinder body contact length 68.4mm, system pressure 400null, maximum swashplate angle 20degree, pressure-control valve diameter 6mm, Slipper coupling flow leaks 5.6e-2*dpL/min, Port Plate Pair flow leaks 1e-2*dpL/min, Coulomb friction moment loss 7mm, moment of rolling friction loss 3mm, cylinder body rotary inertia 0.02Kgm
2, rotating speed 2100rev/min.
Squeeze cylinder model: the HCD storehouse and the signal library that utilize AMESim, sets up squeeze cylinder model according to the structural principle of squeeze cylinder and power loss
[4]consider the mechanical friction between piston rod and piston cylinder, the internal leakage of auxiliary cylinder, the kinetic energy potential energy of piston rod movement and load respectively, the parameter arranging each element is as follows: master cylinder: piston diameter 730mm, diameter of piston rod 730mm, dead-center position 150mm, dead volume 50000cm
3; Auxiliary cylinder: piston diameter 200mm, diameter of piston rod 150mm, dead-center position 30mm, dead volume 1000cm
3, reveal module gap diameter 0.1mm, reveal module gap length 100mm; Pressure ram: gross mass 5x10
6kg; Load is wherein obtained by industry spot image data.
Inserted valve model: inserted valve comprises valve body and valve seat, is designed by HCD storehouse
[6], consider the local pressure loss of valve, each component parameters information is as follows: valve latus rectum 40mm, area ratio 14.3:1null, valve port diameter 38.5mm, spool quality 0.4kg, spool-10 ~ 10m, spring rate 1N/mm, pretightning force 1N.
Simulation results show: arranging simulation time is 69s, the commitment defini interval time is 0.01s, run and check simulation result, obtaining the extrusion speed curve of extrusion process, pass through post processing, obtain the power characteristic of each dissipative cell of extrusion process, in order to the validity of verification model, simulation result and experimental data contrast, as shown in Figure 5,6, emulation is respectively 63s and 66s with the actual extruding deadline, and the deadline of extruding is basically identical; Due to more satisfactoryization that emulation is considered, although the speed of emulation and power input to machine exist error, the general trend of curve is more or less the same, can the energy consumption of analytical model further.
Energy consumption analysis: energy consumption analysis is carried out to the dissipative cell of model, analyze its power consumption and power loss, comprise the local pressure loss energy consumption of output energy consumption with loss energy consumption, inlet valve of plunger variable pump, the spill losses energy consumption of relief valve, the output energy consumption of squeeze cylinder and lose energy consumption as shown in Figure 7,8.
According to simulation result above, clearly can reflect energy ezpenditure and the damaed cordition of each dissipative cell of extrusion process, by further calculating, known total energy consumption is 1.17kW, the useful work that squeeze cylinder exports accounts for 71.2% of total energy consumption, and what energy loss was maximum is that spill losses accounts for 17.1%, and the energy loss of variable pump accounts for 9.15%, the energy loss of squeeze cylinder accounts for 2.1%, and unknown losses accounts for 0.45%.
Carry out energy consumption improvement: according to the quantization profile data obtained, carry out specific aim improvement, improve energy consumption efficiency.
The operation principle of extrusion process and hydraulic system energy consumption are analyzed, system simulation model is set up by AMESim platform, demonstrates the correctness of model.And obtain the energy consumption curve of extrusion process dissipative cell, quantize energy distribution, shown that crowded overflow energy loss is the main cause causing extruding efficiency not high, relief valve spillway discharge can have been reduced or adopt accumulator to reclaim the energy of loss; Next is that the efficiency of variable pump is not high, and other the variable-flow kind of drive can be adopted to reduce system energy consumption, and this research method and simulation result have certain theoretical foundation to extruder energy saving research.
In sum, be embodiment of the present invention content, and obviously embodiments of the present invention are not limited in this, it can according to different application environment, utilizes of the present inventionly functionally to realize corresponding demand.
Claims (5)
1. extruder extrusion process hydraulic system modeling and energy consumption analysis method, comprise the steps:
The first step: carry out extrusion process energy consumption analysis, plunger variable pump energy consumption analysis, inserted valve valve block energy consumption analysis and squeeze cylinder energy consumption analysis;
Extrusion process energy consumption analysis: observe and energy conversion, element that energy loss is relevant, comprise plunger variable pump, inserted valve, master cylinder, according to input, the output energy consumption relation of element, sets up the power balance equation of system: P
p=η
pp
pi=P
c+ P
v(1); Wherein, P
pi, P
p, η
prepresent the input power of hydraulic pump, power output and efficiency respectively, P
cfor the power output of master cylinder 1, P
vfor the power loss of inserted valve valve block;
Plunger variable pump energy consumption analysis: difference form of leaking is set as follows: the secondary leakage loss q of pump plunger
pp, Slipper coupling leakage loss q
ps, Port Plate Pair leakage loss q
pv, volume compression losses q
pc; In addition, by tripartite for mechanical efficiency loss: the Coulomb friction torque loss T that between pump inner part, relative motion causes
ps, bearing element fricative moment loss T
pr; The torque loss T that pump inner fluid viscous damping causes
pv;
The energy consumption relation of plunger variable pump is set as follows: q
pa=q
pt-Δ q
p=q
pt-(q
pp+ q
ps+ q
pv+ q
pc), T
pi=T
pa+ Δ T
p=T
pa+ T
ps+ T
pr+ T
pv;
The power loss formula of plunger variable pump: Δ P
p=P
pi-P
p=2 π nT
pi-pq
pa; Wherein, q
pa, q
ptactual flow and the theoretical delivery of hydraulic pressure respectively, T
pi, T
pabe respectively motor supply torque and the input torque of hydraulic pressure;
The power loss of inserted valve valve block: the power loss of inserted valve shows as local pressure loss, when fluid enters valve port, diminish rapidly at the area of passage at spool place, form pressure reduction, consumed energy, wherein pressure reduction is relevant with inlet pressure with the opening degree of valve, and the power loss caused because of pressure reduction can represent with following formula: P
v=Δ p
aq
vA; Wherein, Δ p
afor valve port pressure reduction, q
vAfor flowing through the flow of primary valve;
Squeeze cylinder energy consumption analysis: the power loss Δ P of squeeze cylinder
cthere is the mechanical friction loss P between piston rod and piston cylinder
cf, because of cylinder internal leakage formed volumetric loss P
ckand the kinetic energy losses of potential energy P that piston rod movement causes
cr, the power output of squeeze cylinder is P
co, obtain the power balance equation of squeeze cylinder: P
c=P
co+ Δ P
c=P
co+ P
cf+ P
ck+ P
cr;
Second step: set up Simulation Model;
Extrusion process hydraulic system modeling emulates: the hydraulic control system model arranging extrusion process;
Plunger variable pump model is set up;
Squeeze cylinder model is set up;
Inserted valve model is set up;
3rd step: carry out simulation results show;
Simulation results show: arranging simulation time is 69s, the commitment defini interval time is 0.01s, moving model also checks simulation result, obtain the extrusion speed curve of extrusion process, by process, obtain the power characteristic of each dissipative cell of extrusion process, then the energy consumption of further analytical model;
4th step: carry out energy consumption analysis;
Energy consumption analysis: energy consumption analysis is carried out to the dissipative cell of model, analyze its power consumption and power loss, comprise the local pressure loss energy consumption of output energy consumption with loss energy consumption, inlet valve of plunger variable pump, the spill losses energy consumption of relief valve, the output energy consumption of squeeze cylinder and loss energy consumption, and curve map is set up to above-mentioned energy consumption and contrasts, quantize energy distribution;
5th step: carry out energy consumption improvement based on energy consumption analysis; Carry out energy consumption improvement: according to the quantization profile data obtained, carry out specific aim improvement, improve energy consumption efficiency.
2. extruder extrusion process hydraulic system modeling according to claim 1 and energy consumption analysis method, it is characterized in that in described second step, carry out the foundation of plunger variable pump model: the pump housing is oblique tray type axial plunger piston variable pump, comprise valve plate, plunger cavity volume, swash plate plunger connector and swash plate controller three part; Wherein, for valve plate arranges four ports, represent oil-in, oil-out, plunger hydraulic fluid port and cylinder body corner respectively, its oil-in, oil-out are connected with the high pressure chest of valve plate, low pressure chamber respectively, and cylinder body rotates one week, and plunger completes an oil suction and oil extraction; Plunger cavity volume is made up of plunger, hydraulic pressure cavity volume and leakage hole, and one end connects plunger hydraulic fluid port, and the other end connects swash plate plunger connector; The power transmission shaft inertia input of swash plate plunger connector connects motor, and when cylinder body rotates, connector can actuation plunger move back and forth, and realizes oil suction and oil extraction function according to output corner; Swash plate controller connects the swash plate inertia input of swash plate plunger connector, can be used for regulating swashplate angle, controls pump delivery.
3. extruder extrusion process hydraulic system modeling according to claim 2 and energy consumption analysis method, it is characterized in that the Parametric Representation of described variable pump is as follows: plunger radial position 0.04m, diameter of plunger 28mm, plunger number 9null, diameter of plunger gap 0.01mm, plunger, cylinder body contact length 68.4mm, system pressure 400null, maximum swashplate angle 20degree, pressure-control valve diameter 6mm, Slipper coupling flow leaks 5.6e-2*dpL/min, Port Plate Pair flow leaks 1e-2*dpL/min, Coulomb friction moment loss 7mm, moment of rolling friction loss 3mm, cylinder body rotary inertia 0.02Kgm
2, rotating speed 2100rev/min.
4. extruder extrusion process hydraulic system modeling according to claim 1 and energy consumption analysis method, it is characterized in that in described second step, carry out the foundation of squeeze cylinder model: the parameter arranging each element is as follows: master cylinder: piston diameter 730mm, diameter of piston rod 730mm, dead-center position 150mm, dead volume 50000cm
3; Auxiliary cylinder: piston diameter 200mm, diameter of piston rod 150mm, dead-center position 30mm, dead volume 1000cm
3, reveal module gap diameter 0.1mm, reveal module gap length 100mm; Pressure ram: gross mass 5x10
6kg; Load is wherein obtained by collection in worksite data.
5. extruder extrusion process hydraulic system modeling according to claim 1 and energy consumption analysis method, it is characterized in that in described second step, carry out the foundation of inserted valve model: each component parameters information is as follows: valve latus rectum 40mm, area ratio 14.3:1null, valve port diameter 38.5mm, spool quality 0.4kg, spool-10 ~ 10m, spring rate 1N/mm, pretightning force 1N.
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| US20040102935A1 (en) * | 2001-02-19 | 2004-05-27 | Marc Lacroix | Method for regulating a property of a product derived from a chemical transformation |
| CN101712207A (en) * | 2009-09-08 | 2010-05-26 | 广东工业大学 | High performance and energy-saving double-acting hydrostatic press driven by servo motor |
| CN103745279A (en) * | 2014-01-24 | 2014-04-23 | 广东工业大学 | Method and device for monitoring energy consumption abnormity |
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|---|---|---|---|---|
| US4793954A (en) * | 1987-08-17 | 1988-12-27 | The B. F. Goodrich Company | Shear processing thermoplastics in the presence of ultrasonic vibration |
| US20040102935A1 (en) * | 2001-02-19 | 2004-05-27 | Marc Lacroix | Method for regulating a property of a product derived from a chemical transformation |
| CN101712207A (en) * | 2009-09-08 | 2010-05-26 | 广东工业大学 | High performance and energy-saving double-acting hydrostatic press driven by servo motor |
| CN103745279A (en) * | 2014-01-24 | 2014-04-23 | 广东工业大学 | Method and device for monitoring energy consumption abnormity |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN112161803A (en) * | 2020-09-16 | 2021-01-01 | 上海市轴承技术研究所 | Rolling bearing life-span energy consumption testing machine under combined load |
| CN112161803B (en) * | 2020-09-16 | 2022-09-13 | 上海市轴承技术研究所 | Rolling bearing life-span energy consumption testing machine under combined load |
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| CN104785568B (en) | 2017-03-15 |
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