Control and Drive Systems for Open-die Forging Presses

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

Control and Drive Systems for Open-die Forging Presses | Technical Information 3/16


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



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



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



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

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Valve Technology



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



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



Piping

Engineering

Production

Installation



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



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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



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)



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.



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.



Documents

Control and Drive Systems for Open-die Forging Presses