Modeling and Simulation of YP3500 Hydraulic Ceramic Press

Proceedings of the Eighth International Conference on Fluid Power Transmission and Control

(ICFP 2013)

Edited by: Yongxiang Lu

Qingfeng Wang

Bingfeng Ju

Jun Zou

World Publishing Corporation

Organized by

Institute of Mechatronic Control Engineering, Zhejiang University

Co-sponsored by

Ministry of Education of the People's Republic of China National Natural Science Foundation of China

Chinese Mechanical Engineering Society

The State Key Laboratory of Fluid Power Transmission and Control Chinese Fluid Power Transmission and Control Society

Natural Science Foundation of Zhejiang Province of China China Hydraulics Pneumatics & Seals Association

K.C.Wong Education Foundation

HOYEA Co., Ltd

Shanghai Lixin Hydraulic Co., Ltd

Festo (China) Ltd

Bosch Rexroth China

SMC (China) Co., Ltd

Honorary Chair

Yongxiang Lu,

Chair, the Academic Committee of the State Key Lab of Fluid Power Transmission and Control, Zhejiang University,China

International Program Committee

Co-chairs: Prof. Ying Chen, Zhejiang University, China

Prof. Qingfeng Wang, Zhejiang University, China

Members: Prof. Andrew Plummer, University of Bath, UK

Prof. Baosen Sha, China Hydraulics Pneumatics and Seals Association, China

Prof. Bin Yao, Purdue University, USA

Prof. Guangshang Zeng, Beihang University, China

Prof. Guobiao Wang, National Natural Science Foundation of China, China

Prof. Huayong Yang, Zhejiang University, China

Prof. Hubertus Murrenhoff, RWTH Aachen University, Germany

Prof. Jürgen Weber,Dresden University of Technology, Germany

Prof. Kalevi Huhtala, Tampere University of Technology, Finland

Prof. Kevin Edge, UK

Prof. Kim Stelson, University of Minnesota, USA

Prof. Monika Ivantysynova, Purdue University, USA

Prof. Peter Achten, Innas BV, Netherlands

Prof. Peter Krus, Link?pings Universitet, Sweden

Prof. Richard Burton, University of Saskatchewan, Canada

Prof. Shinichi Yokota, Tokyo Institute of Technology, Japan

Prof. Tapio Virvalo, Tampere University of Technology, Finland

Prof. Toshiharu Kagawa, Tokyo Institute of Technology, Japan

Prof. Xiangdong Kong, Yanshan University, China

Prof. Yuming Wang, Tsinghua University, China

Prof. Zongxia Jiao, Beihang University, China

Prof. Zuwen Wang, Dalian Maritime University, China

Organizing Committee

Chairman: Qingfeng Wang

Members: Bing Xu, Bingfeng Ju, Canjun Yang, Dejun Li, Hao Liu, Huayong Yang, Jun Zou, Wei Li, Xiaodong Ruan, Xin Fu, Ying Chen

General Secretary: Bingfeng Ju,Jun Zou

Members of Secretariat: Dan He, Kaimin Guan

A Modelling Approach to Multibody Dynamics of Fluid Power Machinery with Hydrodynamic Lubrication (228)

Per Johansen, Daniel B. R?mer, Torben O. Andersen, Henrik C. Pedersen

Analysis and Numerical Simulation of Leakage Flow of Low Speed High Torque Water Hydraulic Motor’s Piston Pairs (233)

Dianrong Gao, Zhiqiang Wang, Yao Huang

Design and Analysis of a Tubular DC Permanent-magnet Linear Oscillating Motor for the EHA Servo Pump (237)

Huisheng Liang, Zongxia Jiao, Liang Yan, Yang Li, and Longfei Zhao

Development of a CFD Model to Investigate the Characteristic of Oil Films in an Axial Piston Pump (242)

Huayong Yang, Yuechao Song, Bing Xu

Force Balance Analysis of Elastohydrodynamic Effects using a Fluid Structure Interaction Model of External Gear Machine s (251)

Sujan Dhar, Andrea Vacca, Antonio Lettini

Influence of Air Content Entrained in Fluid of Vane Pump with Double Effect Operating Parameters (256)

R. Petrovi?, M. Zivkovic, Z. Wang, D. Rakic, R. Sl avkovic, N. Todic

Investigation on Characteristics of Electro-magnet’s Suction Based on Maxwell (263)

Bo Wu, Zisheng Lian

MCMC-Based Pressure Analysis (270)

Jun-Hong Liu, Heikki Handroos, Heikki Haario, Huapeng Wu

Mechanism Rese arch on Rotating Jet of the Nozzle (275)

Kaisong Wang, Meng Xu, Kai Chen, Qikai Xie

Modeling and Performance Simulation of High-frequency Micro-pump Based on Giant Magnetostrictive Material (281)

Chuanli Wang, Heqing Zhou, Xiaolei Wu, Xia Gao, Yu Huang

Modeling and Simulation of YP3500 Hydraulic Ceramic Press (286)

Tibing Xiao, Zhe Yuan, Yanling Tu, Xingping Jiang, Chaohuan Liang

Modeling and Simulation on Axial Piston Pump with U-shape Silencing Groove (291)

Bin Zhang, Yixiang Wang

Modeling and Simulation of YP3500Hydraulic Ceramic Press Xiao Tibing, Yuan Zhe, Tu Yanling, Jiang Xingping, Liang Chaohuan+

Dept.of Mechatronic Eng.,Guangdong University of Technology,

Guangzhou, China,xiaotb75@https://www.360docs.net/doc/3417404101.html,

+R&D Center, Foshan Henglitai Machinery Co., LTD., Foshan, China

Abstract

Modelling and simulation of hydraulic system of YP3500 Ceramic Press is finished in this paper with the software AMESim. How to build the models for some main hydraulic components of YP3500 ceramic press is introduced. The modelling of 2-way and 3-way proportional throttle cartridge valve, prefill valve, constant pressure variable displacement pump is the emphasis of the paper. The parameters of these simulation models are optimized through the contrastive analysis between simulation results and experimental data. Finally, the contrastive analysis between experimental data and simulation results has proved the validity of the simulation models established in this paper.

Keywords: Ceramic press, system modeling, simulation analysis, experiment

1 Introduction

The hydraulic ceramic press is one of the key equipments of ceramics production line, and it is a typical hydromechatronic system[1]. The hydraulic system of ceramic press is very complex. The design of hydraulic system is mainly by means of experiences, but theoretical research is very little[2]. The lower precision of the beam position and pressure controlling will result in many problems. In this article, the simulation model of hydraulic system of YP3500 ceramic press is established through AMESim. We can find out the problems more easily through simulating the model, and it can be used as a reliable virtual platform for design and optimization of the hydraulic system of YP3500 ceramic press.

2 Working principle analysis of YP3500

type ceramic press

Figure 1 shows the working principle of hydraulic system of YP3500 type ceramic press. The oil circuits of several main actions are introduced as follows:

(1)Mobile beam descending: The pressure oil in the upper tank flows into the upper chamber of main cylinder through the prefill valve and cartridge valve V105. The oil in the lower chamber of main cylinder returns to the tank through the cartridge valve V203 and proportional valve YV202. So the mobile beam descends rapidly.

(2) Inertia pressurizing: no inlet oil line, the mobile crossbeam puts pressure to the powder with its own inertia. Then cartridge valve V105 is opened, and the upper chamber of main cylinder connects with the tank.

(3) Aerofluxus after inertia pressurizing: Pressure oil enters into the lower chamber of main cylinder through cartridge valve V204, V201, proportional valve YV202 and cartridge valve V203. The oil in the upper chamber of main cylinder flows back to the tank by cartridge valve V105. After exhausting, the descending speed of mobile cross beam is controlled by proportional valve YV202, and its working oil circuit is same with mobile beam descending stage.

(4) Pressurizing with low & medium pressure: pressure oil enters into the upper chamber of main cylinder through the cartridge valve V204, proportional valve YV110, cartridge valve V106 and V107. The oil in the lower chamber of main cylinder returns to the upper tank through the cartridge valve V203, proportional valve YV202.

(5) Pressurizing with high pressure: pressure oil enters into the rodless chamber of pressure cylinder through cartridge valve V204, V102, the high pressure oil discharged from the rod chamber of pressure cylinder enters into the upper chamber of main cylinder through the cartridge valve V107.

(6) Mobile beam return: prefill valve and cartridge valve V105 are open, then the upper chamber of main cylinder connect with the upper tank. Pressure oil enters into the lower chamber of main cylinder through cartridge valve V204, proportional valve YV202, cartridge valve V203, driving mobile beam to rise.

Fig.1 Working principle diagram of hydraulic system of YP3500 ceramic press

(7) Ejector movement: the movement of the ejector

usually includes ejection, first decline, second decline and

offside ejection. Pressure oil enters into the rodless

chamber of the ejection cylinder through the cartridge

valve V303, pressure reducing valve group V301, servo

valve YV302, in order to achieve position control of the

lower die.

3 Modeling of main components of YP3500

type ceramic press

3.1 Modeling of the constant pressure pump

The pump used in the ceramic press is a constant-pressure variable displacement pump. When the output pressure is less than the set constant pressure, this pump works with a max displacement. When the output pressure reaches to the set pressure, it adjusts pump displacement automatically to ensure constant pressure and satisfy the system requirements. The output pressure of the pump can be set steplessly in regulating range. The simulation model based on AMESim simulation platform is shown in fig. 2. 3.2 Modeling of 2-way proportion cartridge valve

YP3500 type ceramic press pressure closed loop control is achieved by an ATOS’s LIQZO LE-322 type 2-way proportional flow cartridge valve, which belongs to displacement-electric feedback cartridge proportional throttle valve. In order to simplify the model, considering the pilot valve is a high frequency response valve, the pilot valve directly use 4-way, 3-position, "H" type servo valve provided by standard hydraulic library for the modeling. The main valve part does not have the

corresponding model to use directly. According to its working principle, the model of the main valve can be built by using HCD library. Simulation model of 2-way proportional flow cartridge valve shows in fig.3.

Fig.2 AMESim simulation model of constant

pressure variable displacement pump

3.3 Modeling of 3-way proportion cartridge valve

The speed and position closed-loop control of YP3500 type ceramic press’s mobile beam is achieved by an ATOS’s LIQZO-LE-403 type 3-way proportional flow cartridge valve. The pilot valve’s work principle is same with the 2-way proportional flow cartridge valve, just the main valve core structure is different with the former. The main valve core of the valve distributes a few round holes, which are used for throttle control. The main valve core is hollow structure. Simulation model of 3-way proportional flow cartridge valve is shown in fig.4. 3.4 Modeling of ejector The ejector is used for driving the lower die to make the powder filled and the ceramic tile ejected. There are not corresponding models of the pressure reducing valve group and ejection cylinder to use, so we can build them

by using HCD library. The pressure reducing valve group consists of a two-way cartridge valve and a pressure reducing valve. According to working principle, simulation model is built as shown in fig.5.

4 Simulation analysis and experimental verification 4.1.1 Simulation analysis of the 2-way proportion cartridge valve The flow characteristic is one of important static characteristics of proportional cartridge valve. The control oil pressure is 140 bar, and the control voltage signal of simulation model is a unit slope signal of 0~10V . Simulating the model, the flow characteristic curve is obtained, shown as fig.6. As can be seen from the fig.6, the simulation curve is very close to the performance

curve provided by the product manual.

4.1.2 Simulation analysis of the 3-way proportion

cartridge valve

The pressure drop between two valve ports is set to 5 bar, the flow characteristic simulation curve of LIQZO-LE-403 type proportional flow cartridge valve is shown in fig.7. It is also very close to the performance curve provided by the product manual.

Fig.3 Simulation model of 2-way proportional flow cartridge valve Fig.7

Fig. 6

Fig. 5

Simulation model of ejection system Fig.4 Simulation model of 3-way proportional flow

cartridge valve

Fig.10

Simulation model of YP3500

4.2 Simulation and experimental analysis of constant

pressure variable pump

In order to study the static and dynamic characteristics of the pump, we respectively did pressure-flow characteristic simulation and constant pressure characteristic experiment. Figure 8 is the pressure-flow characteristic simulation curves of constant pressure pump. In the low pressure range and constant pressure period, the simulation model is of a good constant pressure effect. Figure 9a and figure 9b show constant pressure characteristic experimental curve and simulation curve of pump. The experiment result shows that the adjustment time of this constant pressure pump is very long. In another word, its dynamic characteristic is not good.

4.3 Simulation analysis of mobile beam According to press hydraulic diagram ，simulation model is built shown as in fig. 10. After setting simulation parameter, running the simulation. The simulation pressure curve and the experimental pressure curve are respectively shown in fig.11a and fig.11b. As can be seen

from fig.11a, the working pressure in various suppression

stages are respectively 67 bar, 88 bar, 172 bar and 352 bar, and the errors to the experimental results are respectively

4 bar, 3 bar, 0.1 bar and 0.3 bar. For large tonnage pressure machine, these errors are very small. It is fully demonstrated the correctness of the simulation model. Fig.8 Pressure-flow curve Pump outlet pressure [bar]

P u m p o u t l e t f l o w [L /m i n ] Fig.9a Experimental curves Fig.9b Simulation curves T=318 ms 66bar Pressure setting time Step signal Pump outlet pressure [bar] T=441 ms 66.758bar

4.4 Simulation and experimental analysis of the

ejector

Figure 12a shows ejector cylinder displacement and

servo valve voltage in simulation. Figure 12b shows the work pressure curves of the ejection cylinder and the outlet pressure of the reducing cartridge valve in

simulation. Figure 12c shows the experimental results. The trend and value of curves in simulation and experimental results are consistent. It shows that the simulation model is reasonable. But there is overshoot in the experimental displacement curve, and pressure curve in simulation is very smooth. The main reason is that some parameters of the simulation model, such as the oil elastic modulus, frictional force and oil viscosity, are very difficult to determine precisely. 5 Conclusions The contrastive analysis between experimental data and simulation results proved the validity of the simulation models established. A reliable virtual console for the ceramic press parameters optimization design is provided. The simulation model needs further

optimization through simulation and experiment.

References [1] Zhang Bailing. Automatic hydraulic press. Nanchang:

Jiangxi Science and Technology Press, 2000.

[2] Fengchang Yin, Qian Jin. Domestic Ceramic ceramics

Machines Found and Future Prospects. China Ceramic Industry,1999,6(2):22-24.

[3] FU Yongling, Qi Xiao Ye. AMESim System

Modeling and Simulation -- From Novice to Professional [M]. Beijing: Beijing Aerospace University Press, 2006. Fig.11a Pressure curve in simulation

Hydraulic cylinder ’s big

cavity pressure [bar] Fig.11b Experimental pressure curve D(6.442,352.470) C(5.986,172.564) B(4.192,85.611)A(3.283,71.315) 127ms 158ms 311ms 153ms

Fig. 12b Pressure curves in simulation Fig. 12a Ejector cylinder displacement and servo

valve voltage in simulation

Fig. 12c Experimental curves Cylinder displacement [mm]

Input signal [V]

Reducing valve outlet pressure [bar]

Rodless cavity pressure [bar] Rod cavity pressure [bar] Ejector displacement[mm]Pressure reducing valve outlet pressure [MPa] Rod cavity pressure [MPa] Rodless cavity pressure [MPa] Servo valve voltage [V]Time [s] A m p l i t u d e