With the development of production technology, a new problem has arisen on the factory floor. There are now too many hydraulic power units, which has resulted in a great waste of resources. At the same time, the working process of the pump station causes excess pressure. It also leads to excess flow, which shortens the service life of hydraulic oil. This paper proposes a new intelligent multi-pump integrated hydraulic power unit system to address this problem. Specifically, the system features automatic control and a variety of detection and protection means. As a result, it offers good stability and high reliability. Additionally, users can easily set and modify a variety of parameters.
Components of the hydraulic power unit
The composition of the hydraulic power unit hydraulic station from the pump group, tank components, temperature control components, two-stage accumulator, filtering devices, detection devices and control systems combined, as shown in Figure 1.
1.1 Pumpsets
The pumping station consists of a cascade of quantitative pumping units and variable frequency pumping units. Variable flow control is available to change the number of pumps running and the frequency of the variable frequency pumping unit to match the flow rate. At the same time, each branch circuit is tested.
1.2 Fuel tank assembly
The main functions of the offline filtration integrated design tank are oil storage, oil temperature regulation, separation of gas and filtration of precipitated dirt.
1.3 Accumulator assembly
In order to further reduce the pressure fluctuations of the remote hydraulic pipeline set the pump station level accumulator group and work accumulator group. The control system relies on two-stage pressure feedback. It also uses flow feedback to form a closed-loop control. This setup maintains stable hydraulic system pressure. The two-stage accumulator co-ordination, taking into account the corresponding performance and flow.
1.4 Detection and control devices
To ensure the safe, reliable, and continuous operation of the pumping station, PLC and human-machine interface systems are used. This approach also helps to prolong the service life of the pumping station. It mainly includes pressure status detection, oil temperature closed-loop adjustment, liquid level intelligent alarm, oil detection and so on.
Design of PLC control system
The hydraulic power unit powers the hydraulic equipment in the various rooms of the workshop. The integrated hydraulic power unit operation process:
1) start the hydraulic power unit, the control system according to the situation to open the offline filter and temperature control unit, delayed open the single main quantitative pump, the system and the energy storage device loading;
2) According to the opening of each room, the control system according to the database of each piece of equipment in the past flow value, configure the pumping station group, quantitative pumps began to work, variable frequency pumping group into a ready state;
3) after the work of the chamber hydraulic equipment, the system according to the pressure change of the accumulator of each chamber, real-time adjustment of the variable frequency pumping unit oil supply to meet the process requirements.
4) When the room closes or pauses, the control system resets the rated output flow rate according to the number of devices opened. It then re-opens or closes the quantitative pumping unit when the variable-frequency pumping unit fails to meet the requirements.
The background data block utilised to design the working retrieval database and fault diagnosis database of the hydraulic power unit group. Through the human-computer interface can be flexible control and detection of hydraulic pump station oil pump motor unit operation status. The background control programme can achieve automatic adjustment of the flow can also be real-time correction of the database flow parameters. To maximise energy saving and consumption reduction. For the transformation of the parameters, the control system can achieve fault diagnosis and alarm. At the same time can achieve closed-loop control of the hydraulic system.
After the centralised intelligent hydraulic power unit has been in actual operation, the system has proven to be reliable. It consumes low power and has perfect functionality. The operation is simple, and the maintenance is easy. After putting it into operation, we have greatly improved the operation of the hydraulic power unit. We have also enhanced its maintenance. Additionally, we have realised its centralised control and operation monitoring.
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