伺服压机基础知识课件.ppt

1、12I.Overview of Servo Press Technology 伺服压机技术概览伺服压机技术概览II.Comparison between Servo and Mechanical Press 伺服压机与机械压机对比伺服压机与机械压机对比III. Servo Press Presentation CONTENT目录目录3nAdvantage 优势优势 Full load capacity at low SPM 低低SPM也可以达到满负荷吨位也可以达到满负荷吨位 W/o flywheel/clutch/brake. Easy for maintenance 没有飞轮没有飞轮/离合器

2、离合器/制动器，易于维护制动器，易于维护 Better for automation to increase the output 自动化方面更易增加输出自动化方面更易增加输出 Programmable motion curve, reduce the requirement for the die and blank material 可设定的滑块曲线，降低对模具和板料材料的要求可设定的滑块曲线，降低对模具和板料材料的要求I.OVERVIEW OF SERVO PRESS TECHNOLOGY 伺服压机技术概览伺服压机技术概览4nDisadvantage 劣势劣势 Higher lifeti

3、me cost 成本更高成本更高 Sophisticated control system 控制系统更复杂控制系统更复杂 Higher maintenance level 设备维护技术要求更高设备维护技术要求更高I.OVERVIEW OF SERVO PRESS TECHNOLOGY 伺服压机技术概览伺服压机技术概览5. Comparison between Servo and Mechanical Press 伺服与机械压机对比伺服与机械压机对比nGeneral design of mechanical press 机械压机结构机械压机结构Upright立柱立柱Bed底座底座Flywheel

4、飞轮飞轮Clutch/Brake离合离合/制动器制动器Motor电机电机Slide滑块滑块MB移动工作台移动工作台Crown横梁横梁Driving驱动驱动6nAdvantage of mechanical press 机械压机优势机械压机优势 Technology more mature 技术更成熟技术更成熟 Lower lifetime cost 成本更低成本更低 Standard maintenance and spare parts 维护维护/备件要求更简单备件要求更简单. Comparison between Servo and Mechanical Press 伺服与机械压机对比伺服

5、与机械压机对比7 7Servo press伺服压机伺服压机Mechanical press机械压机机械压机Main Drive主驱动主驱动Servo motor伺服电机AC motor交流电机Drive Mode驱动方式驱动方式Direct drive伺服驱动Flywheel + Clutch / Brake飞轮+离合/制动器Motion Curve动作曲线动作曲线Programmable可编程Fixed固定Slide Stroke滑块行程滑块行程Adjustable可调节Fixed固定Automation integration自动化集成自动化集成Better更好Good好Cost 费用费用

6、High高Low低Lifetime cost使用成本使用成本High高Low低nComparisonoverview 对比对比-概览概览. Comparison between Servo and Mechanical Press 伺服与机械压机对比伺服与机械压机对比Press压机压机Specs规格规格8Unit单位单位Servo伺服压机伺服压机Mechanical机械压机机械压机Tonnage吨位吨位Ton吨吨20002000Rated stroke公称压力行程公称压力行程 Mm毫米毫米813Stroke滑块行程滑块行程Mm毫米毫米1100（eccentric曲柄）1300（link多连杆）

7、1400（link多连杆）Line speed整线速度整线速度SPM1818Drawing speed拉深速度拉深速度SPM51218Micro inch寸动寸动SPM1（full load满载）36nComparisonspecification for tandem line 对比对比-串联生产线规格串联生产线规格. Comparison between Servo and Mechanical Press 伺服与机械压机对比伺服与机械压机对比Specs规格规格Press压机压机9Unit单位单位Servo伺服压机伺服压机Mechanical机械压机机械压机TonnageTon吨吨2000

8、2000Rated stroke Mm毫米毫米813StrokeMm毫米毫米250 - 762（eccentric）762（eccentric）SpeedSPM1-2510-25Pendulum speedSPMMax. 35N/AnComparisonspecification for transfer 对比对比-. Comparison between Servo and Mechanical Press 伺服与机械压机对比伺服与机械压机对比Specs规格规格Press压机压机10nComparisonStructure 对比对比-结构结构. Comparison between Serv

9、o and Mechanical Press 伺服与机械压机对比伺服与机械压机对比11nComparisonDrive 对比对比-驱动驱动Servo motor伺服电机伺服电机Motor Flywheel飞轮飞轮. Comparison between Servo and Mechanical Press 伺服与机械压机对比伺服与机械压机对比1212nComparison Stamping operation 对比对比-冲压过程冲压过程Save time节省时间节省时间Servo伺服压机伺服压机Mechanical机械压机机械压机 w/o clutch/brakeContinuous oper

10、ation无离合无离合/制动器，连续运行制动器，连续运行Lower contact speed, lower impact接触拉深垫时速度更小，冲接触拉深垫时速度更小，冲击更小击更小Programmable drawing speed, more flexibility拉深速度可编程，更灵活拉深速度可编程，更灵活BDC holdingLess residual stress下死点停顿，剩余应力更小下死点停顿，剩余应力更小 Slow upstrokeLess cushion impact滑块回程速度慢，对拉滑块回程速度慢，对拉深垫冲击更小深垫冲击更小Quicker upstroke滑块回程速度更

11、快滑块回程速度更快Slide motion start滑块开始运行滑块开始运行Slide up滑块回程滑块回程. Comparison between Servo and Mechanical Press 伺服与机械压机对比伺服与机械压机对比1313nComparison Efficiency 对比对比-效率效率 More efficiency than eccentric mechanical press 伺服压机比机械偏心轮压机更具效率伺服压机比机械偏心轮压机更具效率Servo press伺服压机Eccentric Mechanical press机械偏心轮压机Same drawing s

12、peed相同的拉深速度. Comparison between Servo and Mechanical Press 伺服与机械压机对比伺服与机械压机对比22 SPM15.81616 SPMnComparison Efficiency 对比对比-效率效率 Similar efficiency with link type mechanical press 伺服压机与机械多连杆压机效率相当伺服压机与机械多连杆压机效率相当Mechanical Link press机械多连杆压机Servo Eccentric press伺服偏心轮压机. Comparison between Servo and Me

13、chanical Press 伺服与机械压机对比伺服与机械压机对比1515nComparison - Load capacity 对比对比-载荷载荷 Servo press has less capacity 伺服压机能达到的载荷更小伺服压机能达到的载荷更小l For example: before BDC 180mm 例：在下死点前例：在下死点前180mm 2000T rocker link mechanical press reach above 1000T 2000T多连杆机械压机能达到多连杆机械压机能达到1000T载荷载荷 2000T eccentric servo press rea

14、ch only 600T 2000T伺服偏心轮压机只能达到伺服偏心轮压机只能达到600TServo PressMechanical Press. Comparison between Servo and Mechanical Press 伺服与机械压机对比伺服与机械压机对比1616nComparison - Energy capacity 对比对比-能量载荷能量载荷Mechanical press lower speed less available energy 机械压机在低速时能量较小机械压机在低速时能量较小Servo press full energy in lower speed伺服压

15、机在低速时依然具备满负荷能量伺服压机在低速时依然具备满负荷能量Mechanical机械压机机械压机Servo伺服压机伺服压机. Comparison between Servo and Mechanical Press 伺服与机械压机对比伺服与机械压机对比171717nComparison - Energy capacity 对比对比-能量载荷能量载荷Normally line working speed is between 10-16spm 通常情况下整线的运行速度在通常情况下整线的运行速度在10-16spm之间之间Mechanical press has higher energy th

16、an servo press at line working spm 在整线正常的运行速度下，机械压机比伺服压机能量高在整线正常的运行速度下，机械压机比伺服压机能量高. Comparison between Servo and Mechanical Press 伺服与机械压机对比伺服与机械压机对比伺服/机械压机载荷对比连续工作能量（KJ）1818nComparison Control system _ Motor drive 对比对比-控制系统控制系统_电机驱动电机驱动Mechanical press机械压机机械压机Servo press伺服压机伺服压机3 400V / 50-60HzPowe

17、r supply电源电源KSINAMICSSINAMICSAIMALMDrive-CLiQSIEMENS SIEMENSSINAMICSMM1PH835x-.D1主电机主电机. Comparison between Servo and Mechanical Press 伺服与机械压机对比伺服与机械压机对比Power supply电源电源电容模块电容模块来自来自WKC Chemnitz的预充电电柜的预充电电柜冷却装置冷却装置主驱动主驱动ALM进给进给运动缓冲运动缓冲预充电预充电电能储存系统电能储存系统放电回路放电回路1919nComparison Control system _ Safety

18、and logical control 对比对比-控制系统控制系统_安全和逻辑控制安全和逻辑控制Servo and mechanical press: Same 伺服和机械压机：相同伺服和机械压机：相同. Comparison between Servo and Mechanical Press 伺服与机械压机对比伺服与机械压机对比快速快速I/O接口接口2020nComparison Press Line Control 对比对比-冲压线控制冲压线控制Servo and mechanical press: Same 伺服和机械压机：相同伺服和机械压机：相同Whole line run in s

19、ynchronize model 整线以同步模式运行整线以同步模式运行Feeder start/stop synchronize with press 机械手启机械手启/停与压机同步停与压机同步Have the energy storage for power supply fault protection 具备能源储备，以便在电源故障时保护设备具备能源储备，以便在电源故障时保护设备 . Comparison between Servo and Mechanical Press 伺服与机械压机对比伺服与机械压机对比整线控制（同步控制器）设定点信号编码器信号SSI信号输出到Simotion控制器

20、的信号2121nComparison Press Line Function 对比对比-整线功能整线功能 Both have offline simulation/optimization function 都具备离线模拟都具备离线模拟/优化功能优化功能 . Comparison between Servo and Mechanical Press 伺服与机械压机对比伺服与机械压机对比质量质量速度增加时可能速度增加时可能掉件掉件-复杂-拉深深度-拉深速度-材料，涂层-模具状态-润滑-灰尘，白点运动同步运动同步危险：危险：提速时吸盘可提速时吸盘可能会与零件产能会与零件产生滑动或脱离生滑动或脱离滑

21、动脱离碰撞取决于碰撞取决于-零件变形零件变形-端拾器变形端拾器变形2222nComparison Press Line Function 对比对比-整线功能整线功能 Press line start up_Curve testing function 整线开动整线开动_曲线测试功能曲线测试功能Servo press line: Use Pulse handle testing curve 伺服冲压线：采用微动摇杆测试曲线伺服冲压线：采用微动摇杆测试曲线Mechanical press line: Use Snoop function Testing Curve 机械冲压线：采用监控功能测试曲线

22、机械冲压线：采用监控功能测试曲线 . Comparison between Servo and Mechanical Press 伺服与机械压机对比伺服与机械压机对比2323nComparison Press Line Function 对比对比-整线功能整线功能Same ADC function and ADC time Intermediate Gear/Pinion Shaft 中间齿轮中间齿轮/齿轮轴齿轮轴-Eccentric Gear 偏心轮偏心轮-Link drive (Drag Link) 连杆传动（拉杆）连杆传动（拉杆）-Slide 滑块滑块. SERVO PRESS 31nD

23、rive System ( Eccentric ) 驱动系统（偏心轮压机）驱动系统（偏心轮压机）Gearbox变速箱变速箱-Intermediate Gear/Pinion Shaft 中间齿轮中间齿轮/齿轮轴齿轮轴-Eccentric Gear 偏心轮偏心轮-Pitman 摇杆摇杆-Plunger/Slide 导柱导套导柱导套/滑块滑块Intermediate Gear中间齿轮中间齿轮Eccentric Gear偏心轮偏心轮Pitman摇杆摇杆Plunger导柱导柱Plunger Guide导套导套 Driving Chain: 驱动链：驱动链：. SERVO PRESS 8x90Gibs

24、四角八面导轨四角八面导轨 Hydraulic Overload Protection 液压过载保护液压过载保护Pressure Point压点压点Hydraulic overload protection液压过载保护液压过载保护Gib导轨导轨Die height adjustment装模高度调节装模高度调节Slide body滑块滑块nSlide 滑块滑块32. SERVO PRESS 33nMoving Bolster 移动工作台移动工作台. SERVO PRESS 34nNC Hydraulic Cushion 数控液压垫数控液压垫 2,4,6,8 points 可选可选2,4,6,8点点

25、 200-600Ton 可选可选200-600吨吨. SERVO PRESS 35Programmable multi-pressure during forming process 成型过程中可编辑多处压力成型过程中可编辑多处压力 With Pre-Acceleration function 带有预加速功能带有预加速功能Pressure build up function 建压功能建压功能With ejection stroke function 可顶起至取料点可顶起至取料点With locking function 有闭锁有闭锁Slide motion curve滑块曲线滑块曲线 Pres

26、sure build up建压建压Drawing stroke拉深行程拉深行程Maximum die cushion stroke拉深垫最大行拉深垫最大行程程Locking闭锁闭锁 Ejection Stroke顶起到取料点顶起到取料点Position control位置控制位置控制Pressure control压力控制压力控制Position control位置控制位置控制Die cushion curve拉深拉深垫曲线垫曲线nNC Hydraulic Cushion 数控液压垫数控液压垫. SERVO PRESS 36nControl Architecture of 2500 ton 2

27、500T控制结构控制结构Machine safety机器安全Safety I/O安全I/OCPUSafety安全HMI用户界面用户界面Remote I/O远程I/OMachine I/OServo Drive & Control 伺服驱动&控制 Press Main Control and Safety压机主控和安全3 400V / 50-60HzRKKPower supply电源电源SINAMICS S120 CU320ALM:16kWKDC-bus max: 720VDCSINAMICSSINAMICSAIMALMSINAMICSSINAMICSMM MMSINAMICSMMSINAMIC

28、SMMSINAMICSMM1FW4 800kW1PH835x-.D11PH835x-.D1Drive-CLiQSIEMENS SIEMENSSIEMENS SIEMENS SIEMENS SIEMENSSIEMENSChiller冷却装置冷却装置SINAMICSMMSINAMICSMMSIEMENS SIEMENSSINAMICSMMSINAMICSMM1PH835x-.D1SIEMENSALM InfeedALM进给Main Drive主驱动Kinetic Buffer动作缓冲Pre_Charge预充电Electric Buffer电能缓冲Profinet Machine Encoder机器

29、编码器Handwheel手轮SERVO CONTROL伺服控制SIEMENSSINAMICSMMSIEMENSSINAMICSMMSIEMENS1FW4 800kW1FW4 800kW1FW4 800kW 4 Main Drive Motors 4个主电机个主电机 3 Kinetic Buffer Motors 3个缓冲电机个缓冲电机. SERVO PRESS 37nControl Architecture of 1000 ton 1000T控制结构控制结构Machine safety机器安全Safety I/O安全I/OCPUSafety安全HMI用户界面用户界面Remote I/O远程I/

30、OMachine I/O机器I/OServo Drive & Control 伺服驱动&控制 Press Main Control and Safety压机主控和安全 2 Main Drive Motors 2个主电机个主电机 2 Kinetic Buffer Motors 2个缓冲电机个缓冲电机3 400V / 50-60HzRR+KKPower suply电源电源KKDC-bus max: 720VDCSINAMICSSINAMICSAIM ALMSINAMICSSINAMICS1FW4 800kW MotorMM MMSINAMICSMMSINAMICSMMSINAMICSMM1PH83

31、5x-.D11PH835x-.D1Drive-CLiQSIEMENSSIEMENSSIEMENSSIEMENSSIEMENSSIEMENSSIEMENSSIEMENSChiller冷却装置冷却装置SIEMENSSINAMICSMMMain Drive主驱动Kinetic Buffer动作缓冲Electric Buffer电能缓冲ProfinetHandwheel手轮OACam优化曲线1FW4 800kW MotorALM InfeedALM进给Motion Control运动控制Encoder编码器. SERVO PRESS 38nControl Architecture of Whole S

32、ervo line 整线控制结构整线控制结构. SERVO PRESS 39nEnergy Management System 能量管理系统能量管理系统Time 时间Velocity 速度Torque 转矩Stamping冲压Energy flow of servo press action 伺服电机能量流Energy is stored in the buffering system能量储存在缓冲系统中 Typical Servo Press Energy Conversion 典型的伺服压机能量转换典型的伺服压机能量转换l Acceleration: Electric Energy-Inv

33、erter-Motor-Kinetic energy (Drive Mechanism -Slide motion + Forming) 加速：电能加速：电能-逆变器逆变器-电机电机-动能（驱动机构动能（驱动机构-滑块动作滑块动作+成型）成型）l Deceleration: Kinetic energy-Motor-Inverter (Regeneration)-Power Grid 减速：动能减速：动能-电机电机-逆变器（再生）逆变器（再生）-电能电能. SERVO PRESS 40nHMI 人机界面人机界面Multifunction HMI Screen, easy for Servo O

34、peration 多功能人机界面，易于操作多功能人机界面，易于操作Specified Position Setup Screen位置设定界面位置设定界面Motion Curve Monitor Screen滑块动作监控界面滑块动作监控界面Motion Data Input Screen运动参数输入界面运动参数输入界面. SERVO PRESS nMeasurement 测量测量 Variable speed running curve planning - 5th power curve 变速运动曲线编辑变速运动曲线编辑-曲线曲线5l 5th power curve acceleration

35、continuous but jerk discontinuity 曲线曲线5可连续加速，停止不连续可连续加速，停止不连续0306090120150180210240270300330360-4-3-2-101234TCy=3.794secCrank Angle()SE4-2000:Crankshaft Motion Profile (0kJ,11.0-18spm:13spmWorkCycle)Drawing Stroke= 250mm11spm,acc./dec.Torque= 4x100% Rated Torque Td/kN.mncs/10spmm/200rad/sstCy/2s. SE

36、RVO PRESS nMeasurement 测量测量 Various variable speed running curve planning - 7th power curve 多变速曲线编辑多变速曲线编辑-曲线曲线7l 7th power curve acceleration/torque smooth and jerk continuous 曲线曲线7加速加速/转矩平滑且停止连续转矩平滑且停止连续l 7th power curve is better than 5th power curve in reducing vibration 曲线曲线7在减少震动方面比曲线在减少震动方面比曲

37、线5表现更好表现更好00.511.522.533.5-5-4.5-4-3.5-3-2.5-2-1.5-1-0.500.511.522.533.544.553.717Cycle Time(sec)SE4-2000: Motion Profile of Crankshaft(0kJ,6.9-22spm:12spmWorkCycle)Simulation of LS4-2400G Stroke=350mm+0mm 13spm,acc./dec.Torque= 4x250% Rated Torque Td/kN.mncs/10spmm/200rad/ssCrankAngle/10000.511.522

38、.533.5-5-4.5-4-3.5-3-2.5-2-1.5-1-0.500.511.522.533.544.553.717Cycle Time(sec)SE4-2000: Motion Profile of Crankshaft(0kJ,6.9-22spm:12spmWorkCycle)Simulation of LS4-2400G Stroke=350mm+0mm 13spm,acc./dec.Torque= 4x250% Rated Torque Td/kN.mncs/10spmm/200rad/ssCrankAngle/100. SERVO PRESS nVibration Measu

39、rement 震动测量震动测量 Vibration measurement is less than mechanical press 测量结构显示震动比机械压机更少测量结构显示震动比机械压机更少. SERVO PRESS nMeasurement 测量测量 The motion curve measurement conforms the calculation 运动曲线测量结果与计算结果一致运动曲线测量结果与计算结果一致 Cam angle凸轮角度凸轮角度Stroke滑块行程滑块行程Velocity速度速度Motor torque电机转矩电机转矩. SERVO PRESS 03060901

40、20150180210240270300330360-5-4.5-4-3.5-3-2.5-2-1.5-1-0.500.511.522.533.544.55SE4-2000: Motion Profile of Slide T51_slideangle_2400t_D400U200_max22spmE15d7spm_1Rate.csvTest Data File-Y:ServoDriveTestDataSE4_20008Sep2012_JN_SE4_2000TRC_T51_15d7spm_1cycle.csvSlide Displacement Error(mm)Crank Angle() Ma

41、x of EnvelopeMin of EnvelopeReal Test Curve of 10 Cycles0306090120150180210240270300330360-1.5-1.25-1-0.75-0.5-0.2500.250.50.7511.251.5Crank Shaft Rotation Error()Crank Angle()VOLVO-CD-LS4-2500A/1:连续次数14spm,空载，压机开连续RecordS:PressTestDataVOLVO_CD12Sept2012_JNLS4_2500A_1_PT5(Test time - 2012-09-12-17:4

42、0:03.000) Real Test Curve of 11 CyclesRepeat accuracy of slide, before optimization优化前的滑块重复定位精度Repeat accuracy of slide, after optimization优化后的滑块重复定位精度nMeasurement 测量测量 The position accuracy after optimization conforms to the engineering requirement 优化后的位置精度符合工程需求优化后的位置精度符合工程需求. SERVO PRESS 46nSimul

43、ation curve 曲线模拟曲线模拟 Constant speed mode sinusoid 等速模式等速模式-正弦曲线正弦曲线. SERVO PRESS 47nSimulation curve 曲线模拟曲线模拟 Variable speed mode Rocker Link Drive 变速模式变速模式-连杆传动连杆传动. SERVO PRESS 48nSimulation curve 曲线模拟曲线模拟 Pressure holding mode of BDC 下死点保压模式下死点保压模式. SERVO PRESS 49nSimulation curve 曲线模拟曲线模拟 Multi-

44、stage stamping 多级冲压多级冲压. SERVO PRESS 50nSimulation curve 曲线模拟曲线模拟 Pendulum mode 摇摆模式摇摆模式. SERVO PRESS 51SE4-800SE4-1000SE4-1200SE4-1600SE4-2000SE4-2400SE4-3000Tonnage（KN）吨位）吨位8,00010,00012,00016,00020,00024,00030,000Rated Stroke Above BDC (mm)公称压力行程公称压力行程8888888Slide Stroke (mm)行程长度行程长度1100110011001

45、100110010001000Speed (SPM)速度速度125125125125125125125Max. Die Height (mm)最大装模高度最大装模高度1400140014001500150015001500Slide Adj. (mm)装模高度调节量装模高度调节量300300300350350350350Slide Size（mm）滑块底面尺寸滑块底面尺寸4600*25004600*25004600*25004600*25004600*25004600*25004600*2500Bolster Size（mm）工作台面尺寸工作台面尺寸4600*25004600*25004600

46、*25004600*25004600*25004600*25004600*2500Energy （KJ）能量能量3504005006008009001000n Servo Press Series ( Eccentric ) . SERVO PRESS Mode型号型号Specs规格规格52SL4-800SL4-1000SL4-1200SL4-1600SL4-2000SL4-2400SL4-3000Tonnage（KN）吨位）吨位8,00010,00012,00016,00020,00024,00030,000Rated Stroke Above BDC (mm)公称压力行程公称压力行程888

47、8888Slide Stroke (mm)行程长度行程长度1300130013001300130013001300Speed (SPM)速度速度122122122122122122122Max. Die Height (mm)最大装模高度最大装模高度1600160016001600160016001600Slide Adj. (mm)装模高度调节量装模高度调节量300300300300300300300Slide Size（mm）滑块底面尺寸滑块底面尺寸4600*25004600*25004600*25004600*25004600*25004600*25004600*2500Bolster

48、Size（mm）工作台面尺寸工作台面尺寸4600*25004600*25004600*25004600*25004600*25004600*25004600*2500Energy （KJ）能量能量3504005006008009001000n Servo Press Series ( Link ) . SERVO PRESS Mode型号型号Specs规格规格53n Servo Press ( Link & eccentric type comparison ) In order to get same SPM: Eccentric type servo press need more hig

49、h rotary speed than link type servo press.为达到相同的SPM：偏心轮伺服压机比多连杆伺服压机需要更高的转速With similar SPM: Speed range of crank shaft for eccentric servo press is more wider than link type servo press.相同的SPM：偏心轮伺服压机曲柄轴的速度范围比多连杆伺服压机的更广Compare with eccentric type servo press: link type servo press with lower consume

50、, higher efficiency, lower noise. 与偏心轮伺服压机对比，多连杆伺服压机功耗更低，效率更高，噪音更小Lower speed gear pair with better working condition. 低速齿轮副工作状况更好. SERVO PRESS 曲柄轴最大速度（偏心轮压机）曲柄轴最大速度（多连杆压机）曲柄轴瞬时速度（rpm）周期时间曲柄轴速度范围（多连杆压机）曲柄轴速度范围（偏心轮压机）多连杆压机周期时间偏心轮压机周期时间54With same SPM when deep drawing: Link type servo presss highest