Modernization of the hydraulic system and control system for the movable traverse of a 6300-ton press model P8148
Client:
United Heavy Machinery Plants. OAO "Uralhimmash" (Yekaterinburg)
Year of implementation:
2011-2012
At the Uralhimmash plant, a stamping press manufactured in 1966 is in operation. The press is used for stamping elliptical bottoms. The purpose of modernizing the control system for the 4000/6500-ton press was to meet the requirements of domestic and foreign companies in performing stamping operations for these products.
Issues necessitating modernization:
- Short lifespan of the electromechanical drive components of the valves, leading to increased press downtime for repairs;
- Limited capabilities for adjusting speed and force parameters affecting the quality of stamping;
- Significant time required for die replacement;
- Lack of filtration for the working fluid;
- Absence of monitoring, diagnostic, and information tools for controlling technological processes and the condition of the press's main components;
- Need to restore the centralized grease lubrication system.
An analysis conducted at the plant showed that the long-term operation of the press without major repairs had resulted in significant wear of the press’s main components (stationary traverse, movable traverse with guides, central slide, frame, table with guides), columns, plunger, 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 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, training of plant specialists.
Results of modernization:
- Increased reliability and durability of the press
- Enhanced press control capabilities
- Improved working conditions for press operators and maintenance staff
- Increased press productivity
- Improved product quality
- The press was successfully put into operation
