Development and research of a multistage hydraulic gear-multiplier drive for metallurgical presses

The paper presents one of the solutions to reduce the installed power and increase efficiency of hydraulic pump drive of high power pressing equipment used in metallurgical plants. The authors have developed a multistage hydraulic drive based on a block gear-multiplier. Plungers of all cylinders form a movable block, the cylinders – a stationary one. The mode of operation (reduction, multiplication) is provided by a combination of output cylinders supplying fluid to the power cylinder by switching some of them to drain. Analysis of a four-stage drive with a three-stage multiplier gearbox is presented in comparison with a simple pump drive. A four-stage drive with two output cylinders provides a reduction gear and two multiplier stages, with which a stage of fluid supply to the power cylinder directly from the pumps (pump stage) is combined. Power and kinematic parameters of the drive were determined by the power loading during the working stroke and speed mode during the working cycle (forward (idle and working stroke) and reverse stroke). It is advisable to use a multi-stage drive with a smoothly increasing load over the entire length of the working stroke (upsetting, drawing operations). Analysis of the basic and additional combination of stages for linearly increasing power load, which was determined by the pressure at the beginning of Р₀ , and the maximum pressure at the end of the working stroke Р_max was carried out. In the basic version, a gear stage (idle stroke), pump stage and two multiplier stages (working stroke) are sequentially combined. With an additional combination, the reduction stage covers idle stroke and initial part of the working stroke. Analysis was carried out under the condition of equality of pressure and power of the pumps in stages and the condition of equality of direct stroke time of the compared drives. The ratio of pump capacities was estimated. Dependences of the main parameters of the developed drive, reduction and multiplication factors were obtained. With the accepted initial data, it is possible to reduce the pressure and power of the developed drive pumps (in comparison with the simple one) by 28 – 37 % with an additional combination of stages (increases with an increase of an idle stroke). It is lower for the basic combination by 5 – 9 % (reduction is greater at lower idle stroke values). The use of an additional combination is limited by the ratio P₀/P_max ≤ 0/4.

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