control and drive systems for open-die forging presses
TRANSCRIPT
RE 08114, edition: 2012-06, Bosch Rexroth AG
Control and Drive Systems forOpen-die Forging Presses
Features
Introduction 2Open-die Forging Presses in the Press Plant 3System Elements of an Open-die Forging Press 4Pump Technology 5Valve Technology 6 - 7Cooling and Filter Units, Accumulator Stations, Tanks and Containers 8Control Manifold Blocks 9Piping 10HMI, Electronic Control 11Electronic Control 12Simulation 13Safety and Compliance, Service 14Global Presence, List of References 15
RE 08114 Edition: 2012-06Technical Information
2/16 Technical Information | Control and Drive Systems for Open-die Forging Presses
Bosch Rexroth AG, RE 08114, edition: 2012-06
Introduction
Bosch Rexroth supplies components, power units and complete systems, including engineering, electronic con-trol, HMI, programming and simulation for open-die forging presses incl. all auxiliary systems.
Accumulator station
Unloading manifold block
Return control manifold block
Pump control manifold block
Tank
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Open-die Forging Presses in the Press Plant
Open-die forging is a non-cutting forming process for metals to be formed between two dies by variation of the cross-section.The forging process is carried out with hot work piece.Advantages of a forging process compared to cutting pro-cessing include lower material losses as well as an improve-ment in material consistency.Industrial open-die forging presses work in the range from 5 to 200 MN press capacity.In the open-die forging process, the work piece is formed between two dies by a forge cylinder or forging hammer. The material may flow into areas not covered by the dies.The final shape of the work piece is achieved by continuously adjusting the position of the work piece, by means of a
manipulator, between the individual press strokes.This process is particularly suitable for large work pieces such as crank shafts of marine diesel engines or rollers for the steel or paper industry. Unit weights of up to 250 t are quite common.The planishing mode is a challenge for the press control. The final shape and quality is produced by small high fre-quency cylinder strokes.This requires a dynamic, powerful and robust press frame and drive which allows high stroke frequencies at high forces.The open-die forging presses are generally distinguished between above ground and under ground design.
Push-down press Pull-down press
Main tank
Pre-fill tank
FloorManipulator
Crane
Manifold block
Tank
Floor
Manipulator
Crane
Manifold block
Features: Features: ▶ Lower moving mass ▶ Higher moving mass ▶ Lower foundation costs ▶ Higher foundation costs ▶ Increased fire hazard ▶ Reduced fire hazard ▶ Need for pre-fill equipment
(reservoir, pressure vessel or charging pumps) ▶ A separate pre-fill tank is not necessary
▶ Pre-fill equipment endangered by crane ▶ Free crane movement ▶ Costs for pipe-work ▶ Hydraulic installation on the same level:
– Short piping length – Less compression volume – Better noise level / heat – Compact design
▶ Reduced press height ▶ Accessibility of the press
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Bosch Rexroth AG, RE 08114, edition: 2012-06
System Elements of an Open-die Forging Press
Push-down:
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Boost pump
Variable pumps with diverter block
Filter cool-ing system
Pre-fill tank
Pre-fill valves
Main tank
Control of return cylinder
Accumulator
Forge valve
Pilot pressure control (HPU)
Auxiliaries
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Pilot pressure control (HPU)
Auxiliaries
Variable pumps with diverter block
Boost pump Main tank
Control of return cylinder
Forge valve
Filter cool-ing system
Accumulator
Pull-down:
Auxiliaries
Auxiliaries
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Pump Technology
In open-die forging presses, our new A4VBO450 has in the meantime established itself as standard for forging applica-tions up to 450 bar. This modern high-pressure pump is the result of many years of continuous improvement.For the application in open-die forging presses, our exten-sive pump control range offers modern and proven electro-hydraulic control systems for the exact and dynamic control of displacement, power and operating pressure. The con-nection of these control systems to a higher-level machine control is on request also possible via current field bus systems. Our digital HS4 control system has become a
contemporary standard in the forging press industry:Apart from highly dynamic and very exact control loops for the displacement, pressure and power control, HS4 offers numerous additional advantages. These include for example the perfect connection of the higher-level PLC via Profibus or the very simple, stable control of multi-pump systems via the integrated master-slave functionality.
Size
Vg
[cm
3 ]
Power[kW]
1000
500
750
450
16
45
71
125
250
355
Nominal pressure rangeup to 350 bar
A4VSO
A4FO
Nominal pressure rangeup to 450 bar
A4VBO
43 61 91 131 220 311 385 525 583
117 608169
Type Size Vg [cm3]
nmax[min-1]
Features Data sheet
A4VSO 40 - 1000 1.500 to 3.000
– Variable displacement pump– Long service life– Modular system– Shortest control times– Any installation position
92050
A4VBO 71 - 450 1.500 to 3.000– Variable displacement pump– Favorable power/weight ratio– Bearing flushing
92122
A4FO 16 - 500 1.500 to 4.000
– Fixed displacement pump– Perfect suction behavior– Low noise level– Long service life– Pump combinations possible
91455
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Bosch Rexroth AG, RE 08114, edition: 2012-06
Valve Technology
Rexroth offers an extensive range of on/of pre-fill and high response valves for use in open-die forging presses.Working pressures up to 420 bar - for special applications up to 1,000 bar possible.
2-way cartridge valves Directional functions RE21010Size 16 to 160, Qmax = 25.000 l/min, pmax = 420 bar
Pressure functions RE21050Size 16 to 100, Qmax = 7.000 l/min, pmax = 420 bar
Pre-fill valve Type SF, RE20482 Size 125 to 500 Qmax = 50.000 l/min, pmax = 350 bar
Switching valves size 6 to 32
Proportional valves size 6 to 35
Pre-fill valve, actively switchable Type SFS, RE20473 Size 200 to 300 Qmax = 14.000 l/min, pmax = 350 bar
Actively switching 2/2 directional cartridge valves Size 16 to 100, Type LC2A, RE21040 Qmax = 12.500 l/min, pmax = 420 bar
2/2 directional cartridge valve, actively controllableType LC2A
▶ Actively controllable 2/2 directional cartridge valve („two-stage active cartridges“)
▶ Mounting cavity according to ISO 7368 ▶ Functional diversity due to the use of standard cartridge
cover type LFA ▶ “Passive cartridge” function possible ▶ Variable assignment of the pilot oil ports to the active area ▶ Adjustment-free position switch type Q7 ▶ Redundant spool position monitoring, on request ▶ Valve open position signal, on request ▶ Switching-time optimized check valve function, on
request
Type LC2A 025 ...-1X/.Q7G24… (with LFA . D…)
Highly dynamic high-response valves up to size 160 Qmax = 50.000 l/min, pmax = 420 barSize 63 to 160: RE29135 Size 32, 40 and 50: RE29136
2-way high-response cartridge valveValves of type 2WRCE...-2X/S... are 3-stage high-response valves. They control the quantity and direction of a flow and are mainly used in closed-loop control systems.
▶ Suitable for position, pressure, force and velocity control ▶ Pilot control valve:
2-stage, servo valve size 6 or 10 with mechanical feed-back, trimmed, closes the 2WRCE main stage in case of power loss with applied pilot pressure, the 3WRCE main stage is opened from A to T
▶ Main stage: position-controlled ▶ Integrated control electronics (OBE)
Symbol 2WRC.../S..., simplified
G
A
B
Y X
(A1+A2)
1
6
4
3
2
A5
A4
A3
A2
A1
5
X Z1 Z2 Y
A
B
1
2
A5
A3(A1 + A2)
A1 A2 A4
B
A
X
on
87
65
43
21
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Valve Technology
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Bosch Rexroth AG, RE 08114, edition: 2012-06
Cooling and Filter Units, Accumulator Stations, Tanks and Containers
Tanks and containers in all sizes
Main pump assemblies Cooling and filter units
Hydraulic accumulator stations
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Control Manifold Blocks
Pump control manifold block
Unloading manifold block
Return control manifold block
Bosch Rexroth has customized control blocks for open-die forging presses in the sizes 16 to 180 and for flows from 200 l/min to 30,000 l/min up to a system pressure of 450 bar.
Control block with pre-fill valve
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Bosch Rexroth AG, RE 08114, edition: 2012-06
Piping
Engineering
Production
Installation
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RE 08114, edition: 2012-06, Bosch Rexroth AG
HMIHMI (Human Machine Interface):
▶ Planning and production of a control panel and the complete visualization for the operator
▶ Panel layout, the arrangement and selection of the operating elements according to customer specification
▶ The visualization for the operation of the forging plant is designed according to the plant requirements
Electronic ControlIndraMotion MLC for hydraulic applications
▶ Open – in programming and communication
▶ Scalable – closed-loop control of electric, hydraulic and hybrid drives
▶ Continuously easy – with the engineering tool IndraWorks
▶ Best-in-Class – Motion-Control for hydraulics – expertise in demanding applications
▶ Advantages – perfect hydraulic design
▶ SERCOS III real-time communication system
Programming Communication Specific closed loop control know-how
scalable
open continu-ously easy
Software Engineering
Hydraulic components and systems
12/16 Technical Information | Control and Drive Systems for Open-die Forging Presses
Bosch Rexroth AG, RE 08114, edition: 2012-06
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Electronic Control
HMI Engineering www
Hydraulic axis control
I/O device(4 axis)
Motion logic control with central axis control
Electric drives Hybrid drives Hydraulic drives Field devices
Control system, HMI, engineering: : Ethernet based communication between controls, HMI and higher-level systems.
Controls: Motion logic control (lndraMotion MLC as central system components for motion and logic control).
System bus SERCOS III: For drives, Fast I/0 as well as standard I/0 and safety technology.
Flexible I/0 device in IP20 and IP67: Connection of standard sensors/actuators via field bus systems or SERCOS III.
SERCOS III Field bus
Ethernet TCP/UDP/IP
MLC in Open-die Forging Presses
Pre-fill tank
Forge valve 2WRCE
Pre-fill valve
Return cylinder
Return cylinder
Main cylinder
Accumulator Accumulator
Manipulator Hydraulic control:Manifold block- Return cylinder- Auxiliaries
Operator desk remote mainte-
nance I/O
Diverter manifold block
Hydraulic power unit
Filter, cooling
Variable pumps
Remote mainte-
nance I/O
Emergency Stop
Electric power and control cabinets
Management system
Forge program
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Simulation
Bosch Rexroth uses modern simulation technology methods during quotation and project planning phase in order to be able to make detailed statements about the system behav-ior at an early point in time.The created model allows you to obtain detailed under-standing of the system.
Components can be checked for their usability and adjusted and optimized if necessary. This leads to considerable time and cost advantages, not only in the project planning but also during the commis-sioning.
Customer requirement
Hydraulic concept / component selection / open-loop and/or closed-loop control strategy
Simulation model open-die forging press
System behavior (feasibility, performance, accuracy, identification of weak points and optimization, if necessary)
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Bosch Rexroth AG, RE 08114, edition: 2012-06
Safety and Compliance
Human- and machine safety
▶ Safety certificates ▶ Compliance to national/international directives DIN-EN,
ISO, CE, CCC, GOST-R, UL, NEMA, CSA etc. ▶ Risk assessment and -analysis ▶ Hydraulic and electrical safety control ▶ Good planning and implementation ▶ Bosch internal safety standards ▶ See also RE08511
Machinery Safety C standards
ISO 23125
EN 1010
EN 693
EN 474 ...
IEC 61800-5-2
IEC 62061
ISO 13849
Electronic control
Electric equipment
Risk assessment
Electric drives
Machinery Control Systems
ISO 14121
IEC 61508*
IEC 60204
Machinery Directive
ISO 12100
Design basic laws
EN 982 (ISO 4413)EN 983
(ISO 4414)
PneumaticsHydraulics
A standards:Basis standards
B standards:Generic safety standards
* IEC 61508 is not a harmonized standard according to theMachinery Directive, but it serves as basis for other European harmonized standards.
C standards:Product safety standards
Service
Rexroth offers you professional service products for the complete life-cycle of your machines and installations: From commissioning, securing the availability of spare parts and innovative remote service to extension of the machine life.Preventative maintenace plans, special service concepts, reliable and professional corrective maintenance as well as continuous process optimization complete the range of services offered.
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List of References
Examples of recently performed forging press projects:
Customer / Country End User / Country Year Press ForceWorking pressure
Total Delivery Flow
SMS Meer / Germany Nakamura / Japan 2005 63 / 80 MN 305 / 380 bar 7.280 l/min
Taizhong / China Sinosteel / China 2008 63 / 80 MN 350 bar 12.100 l/min
CERI / China CERI / China 2008 55 / 63 MN 315 bar 11.750 l/min
Lanshi / China - / China 2008 37 / 45 MN 315 bar 8.580 l/min
Taizhong / China Wuxi Da Chang / China 2009 47 / 63 MN 350 bar 10.000 l/min
SMS Meer / Germany Buderus / Germany 2009 80 / 100 MN 350 / 420 bar 13.050 l/min
SMS Meer / Germany Baoshan / China 2009 55 / 60 MN 350 / 420 bar 8.700 l/min
SMS Meer / Germany VSMPO / Russia 2009 40 / 52 MN 350 / 420 bar 7.650 l/min
SMS Meer / Germany Forge Saar / Germany 2009 80 / 100 MN 335 / 420 bar 9.180 l/min
Snecma / France Snecma / France 2011 40 MN 290 bar 2.700 l/min
▶ 67 production- and customizing facilities in 25 countries ▶ Sales and distribution network in over 80 countries ▶ R&D facilities in 3 continents
Global Presence
Bosch Rexroth AG HydraulicsZum Eisengießer 197816 Lohr am Main, Germany Phone +49 (0) 93 52 / 18-0 [email protected] www.boschrexroth.de
© This document, as well as the data, specifications and other information set forth in it, are the exclusive property of Bosch Rexroth AG. It may not be repro-duced or given to third parties without its consent.The data specified above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our information. The information given does not release the user from the obligation of own judgment and verification. It must be remembered that our products are subject to a natural process of wear and aging.
Bosch Rexroth AG, RE 08114, edition: 2012-06
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