System composition and working principle
Sensor: usually installed at the four corners or related parts of the hydraulic press slider, used to monitor the displacement, angle or pressure of the slider at various positions in real time. Common ones include displacement sensors, inclination sensors, etc.
Controller: as the "brain" of the system, it receives signals from the sensor, analyzes and processes these signals, calculates the amount to be adjusted according to the preset leveling algorithm and control strategy, and issues control instructions to the hydraulic actuator.
Hydraulic actuator: generally a hydraulic cylinder or hydraulic motor, etc., according to the instructions of the controller, by changing the flow and pressure of the hydraulic oil to adjust the position and posture of the slider, so as to achieve the purpose of four-corner leveling.
Power source: provides hydraulic power for the entire system, usually composed of a hydraulic pump, a motor, a fuel tank and related hydraulic auxiliary components, to ensure that the hydraulic oil can be supplied to the hydraulic actuator at a stable pressure and flow.
Leveling control method
Conventional PID control: This is a classic control method. By adjusting the three parameters of proportion, integration and differentiation, the output of the system can quickly and accurately track the set value. In the hydraulic press four-corner leveling system, the PID controller calculates the control amount according to the displacement or angle deviation detected by the sensor, and drives the hydraulic actuator to adjust to reduce the deviation until the leveling requirement is met.
Fuzzy control: For the hydraulic press four-corner leveling system, a complex system with nonlinear and time-varying characteristics, fuzzy control has good adaptability. It does not require an accurate mathematical model, but based on the operator's experience and expert knowledge, it fuzzifies the input deviation and deviation change rate into different language variables, and obtains the corresponding control amount through fuzzy reasoning and decision-making to achieve the leveling control of the four corners of the hydraulic press.
Adaptive control: When the working conditions of the hydraulic press change, such as load changes, oil temperature changes, etc., adaptive control can automatically adjust the control parameters to ensure that the performance of the system is always in the best state. For example, model reference adaptive control can continuously adjust the controller parameters according to the deviation between the actual output of the system and the output of the reference model, so that the system can quickly adapt to various working conditions and achieve high-precision four-corner leveling.
Predictive control: By establishing a system prediction model, the output and state changes of the system in the future are predicted, and the control strategy is formulated in advance according to the prediction results to optimize the performance of the system. In the four-corner leveling system of the hydraulic press, predictive control can adjust the action of the hydraulic actuator in advance according to the movement trend of the slider and the load change, and improve the response speed and stability of the leveling system.
Important role and significance
Improve product quality: In many processing processes, such as composite material forming, metal sheet stamping, etc., the levelness of the hydraulic press slider directly affects the thickness uniformity and dimensional accuracy of the product. Through the four-corner leveling system, it can be ensured that the slider remains level during the pressing process, thereby improving the quality and consistency of the product.
Extend equipment life: When the hydraulic press slider is tilted, it will cause uneven force on various parts, aggravate the wear and fatigue damage of the equipment, and reduce the service life of the equipment. The four-corner leveling system can adjust the posture of the slider in time, so that the various parts of the equipment are evenly stressed, reduce wear and damage, and extend the service life of the equipment.
Improve production efficiency: A good four-corner leveling system can make the hydraulic press more stable during operation, reduce downtime caused by slider tilt, and improve production efficiency. At the same time, precise leveling control can also improve the running speed and processing accuracy of the equipment, further improving production efficiency.
Enhance equipment adaptability: Under different processing tasks and process requirements, the hydraulic press needs to adapt to various loads and working conditions. The four-corner leveling system can automatically adjust according to the actual situation, so that the hydraulic press always maintains good performance and enhances the adaptability of the equipment to different production needs.
Application Examples
Composite material forming hydraulic press: In the compression molding process of composite materials such as SMC, BMC, GMT, high-precision pressure and position control are required to ensure the quality of composite products. The four-corner leveling system of the hydraulic press can ensure the horizontality of the slider during the pressing process, so that the composite material is evenly compressed in the mold, and the density uniformity and dimensional accuracy of the product are improved. For example, the composite material compression hydraulic press of Chongqing Jiangdong Machinery Co., Ltd., its matching four-corner leveling system enables the press slider position control accuracy to ≤0.05mm, and the four-corner leveling accuracy is ≤0.05mm.
Isothermal forging hydraulic press: Isothermal forging is an advanced forging process that requires the mold and billet to maintain a constant temperature throughout the forging process, and at the same time, the hydraulic press slider movement accuracy and leveling accuracy are extremely high. The four-corner leveling system ensures the stability and uniformity of the forging process by accurately controlling the position and posture of the slider, and improves the quality and performance of isothermal forged parts.
Large-scale thin-plate stamping hydraulic press: In industries such as automobile manufacturing and home appliance manufacturing, large-scale hydraulic presses are required for the production of large-scale thin-plate stamping parts. Due to the thin thickness of the thin plate material, strict requirements are placed on the uniformity of pressure and the horizontality of the slider during the stamping process. The four-corner leveling system can effectively prevent the slider from tilting, ensure that the thin plate is evenly stressed during the stamping process, avoid defects such as plate deformation and cracking, and improve the quality and pass rate of stamping parts.
If you need high precision hydraulic press, please contact Delishi/Goodsjack Hydraulic Machinery, we can supply custom hydraulic press solution, once get your specificational requirments, then best offer will be provided for you.
Sensor: usually installed at the four corners or related parts of the hydraulic press slider, used to monitor the displacement, angle or pressure of the slider at various positions in real time. Common ones include displacement sensors, inclination sensors, etc.
Controller: as the "brain" of the system, it receives signals from the sensor, analyzes and processes these signals, calculates the amount to be adjusted according to the preset leveling algorithm and control strategy, and issues control instructions to the hydraulic actuator.
Hydraulic actuator: generally a hydraulic cylinder or hydraulic motor, etc., according to the instructions of the controller, by changing the flow and pressure of the hydraulic oil to adjust the position and posture of the slider, so as to achieve the purpose of four-corner leveling.
Power source: provides hydraulic power for the entire system, usually composed of a hydraulic pump, a motor, a fuel tank and related hydraulic auxiliary components, to ensure that the hydraulic oil can be supplied to the hydraulic actuator at a stable pressure and flow.
Leveling control method
Conventional PID control: This is a classic control method. By adjusting the three parameters of proportion, integration and differentiation, the output of the system can quickly and accurately track the set value. In the hydraulic press four-corner leveling system, the PID controller calculates the control amount according to the displacement or angle deviation detected by the sensor, and drives the hydraulic actuator to adjust to reduce the deviation until the leveling requirement is met.
Fuzzy control: For the hydraulic press four-corner leveling system, a complex system with nonlinear and time-varying characteristics, fuzzy control has good adaptability. It does not require an accurate mathematical model, but based on the operator's experience and expert knowledge, it fuzzifies the input deviation and deviation change rate into different language variables, and obtains the corresponding control amount through fuzzy reasoning and decision-making to achieve the leveling control of the four corners of the hydraulic press.
Adaptive control: When the working conditions of the hydraulic press change, such as load changes, oil temperature changes, etc., adaptive control can automatically adjust the control parameters to ensure that the performance of the system is always in the best state. For example, model reference adaptive control can continuously adjust the controller parameters according to the deviation between the actual output of the system and the output of the reference model, so that the system can quickly adapt to various working conditions and achieve high-precision four-corner leveling.
Predictive control: By establishing a system prediction model, the output and state changes of the system in the future are predicted, and the control strategy is formulated in advance according to the prediction results to optimize the performance of the system. In the four-corner leveling system of the hydraulic press, predictive control can adjust the action of the hydraulic actuator in advance according to the movement trend of the slider and the load change, and improve the response speed and stability of the leveling system.
Important role and significance
Improve product quality: In many processing processes, such as composite material forming, metal sheet stamping, etc., the levelness of the hydraulic press slider directly affects the thickness uniformity and dimensional accuracy of the product. Through the four-corner leveling system, it can be ensured that the slider remains level during the pressing process, thereby improving the quality and consistency of the product.
Extend equipment life: When the hydraulic press slider is tilted, it will cause uneven force on various parts, aggravate the wear and fatigue damage of the equipment, and reduce the service life of the equipment. The four-corner leveling system can adjust the posture of the slider in time, so that the various parts of the equipment are evenly stressed, reduce wear and damage, and extend the service life of the equipment.
Improve production efficiency: A good four-corner leveling system can make the hydraulic press more stable during operation, reduce downtime caused by slider tilt, and improve production efficiency. At the same time, precise leveling control can also improve the running speed and processing accuracy of the equipment, further improving production efficiency.
Enhance equipment adaptability: Under different processing tasks and process requirements, the hydraulic press needs to adapt to various loads and working conditions. The four-corner leveling system can automatically adjust according to the actual situation, so that the hydraulic press always maintains good performance and enhances the adaptability of the equipment to different production needs.
Application Examples
Composite material forming hydraulic press: In the compression molding process of composite materials such as SMC, BMC, GMT, high-precision pressure and position control are required to ensure the quality of composite products. The four-corner leveling system of the hydraulic press can ensure the horizontality of the slider during the pressing process, so that the composite material is evenly compressed in the mold, and the density uniformity and dimensional accuracy of the product are improved. For example, the composite material compression hydraulic press of Chongqing Jiangdong Machinery Co., Ltd., its matching four-corner leveling system enables the press slider position control accuracy to ≤0.05mm, and the four-corner leveling accuracy is ≤0.05mm.
Isothermal forging hydraulic press: Isothermal forging is an advanced forging process that requires the mold and billet to maintain a constant temperature throughout the forging process, and at the same time, the hydraulic press slider movement accuracy and leveling accuracy are extremely high. The four-corner leveling system ensures the stability and uniformity of the forging process by accurately controlling the position and posture of the slider, and improves the quality and performance of isothermal forged parts.
Large-scale thin-plate stamping hydraulic press: In industries such as automobile manufacturing and home appliance manufacturing, large-scale hydraulic presses are required for the production of large-scale thin-plate stamping parts. Due to the thin thickness of the thin plate material, strict requirements are placed on the uniformity of pressure and the horizontality of the slider during the stamping process. The four-corner leveling system can effectively prevent the slider from tilting, ensure that the thin plate is evenly stressed during the stamping process, avoid defects such as plate deformation and cracking, and improve the quality and pass rate of stamping parts.
If you need high precision hydraulic press, please contact Delishi/Goodsjack Hydraulic Machinery, we can supply custom hydraulic press solution, once get your specificational requirments, then best offer will be provided for you.
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