Modernization of a 40/65 MN vertical hydraulic double-action press
Client:
United Heavy Machinery Plants. OAO "Uralhimmash" (Yekaterinburg)
Year of implementation:
2011-2012
A stamping press, manufactured in 1966, is operated at the Uralhimmash plant for stamping elliptical bottoms. The goal of modernizing the 4000/6500-ton press control system was to meet the requirements of both domestic and foreign companies for conducting stamping operations of these products.
Issues necessitating modernization:
- Short lifespan of the electromechanical drive components of the valves, resulting in increased press downtime for repairs;
- Limited capabilities for adjusting speed and force parameters, affecting stamping quality;
- Significant time required for die replacement;
- Lack of filtration for the working fluid;
- No monitoring, diagnostics, or information tools for controlling technological processes and monitoring the condition of the press's key components;
- Need to restore the centralized grease lubrication system.
An analysis at the plant revealed that the prolonged operation of the press without major repairs had led to significant wear of the press’s main components (stationary traverse, movable traverse with guides, central slide, frame, table with guides), columns, plungers, and guide bushings of the slide's hydraulic cylinder, as well as the lifting, clamping, and table movement hydraulic cylinders. The slide clamping cylinders were missing. All of this required a major overhaul of the press.
Work performed:
- Modernization of the hydraulic system, piping system, lubrication system, instrumentation, and automated process control system (APCS) of the stamping press.
- Manufacturing and delivery of a complete set of hydraulic equipment, pipes, and connection elements for the press's piping system.
- Delivery of the press control cabin with a control panel, electrical equipment cabinets, and automation system.
- Installation of fluid level sensors in the hydraulic and air accumulators of the press's pump-accumulator station.
- Delivery and installation of a centralized grease lubrication system.
- Supervisory installation and training of plant specialists.
Results of modernization:
- Increased reliability and durability of the press
- Expanded control capabilities of the press
- Improved working conditions for the press operator and maintenance staff
- Increased press productivity
- Improved product quality from the press
- The press was successfully put into operation
