Forming Machine, in Particular Forging Hammer, and Method for Controlling a Forming Machine

Abstract

The present invention relates, in particular, to a forging hammer comprising a striker and a hydraulic linear drive that is coupled to the striker and is designed to drive the striker, which drive comprises a hydraulic circuit having a servo-motor hydro pump, a hydraulic cylinder, in particular a differential cylinder, which is fluidically connected downstream of the hydro pump via a directional valve module, and a servo-motor hydro generator, which is fluidically connected downstream of the hydraulic cylinder via the directional valve module, and comprising in addition a control unit configured at least for the simultaneous control of the hydro pump, the hydro generator and the directional valve module.

Claims

1-15. (canceled)

16. A forging hammer, for machining workpieces by forming, comprising: a striking tool; a hydraulic linear drive coupled to the striking tool and configured for driving the striking tool; a hydraulic circuit comprising a servomotor-assisted hydro pump; a hydraulic cylinder, in particular a differential cylinder, which by way of a multi-way valve assembly in terms of fluid technology is disposed downstream of the hydro pump; a servomotor-assisted hydro generator which by way of the multi-way valve assembly in terms of fluid technology is disposed downstream of the hydraulic cylinder; and a control unit which is conceived for at least controlling the hydro pump, the hydro generator, and the multi-way valve assembly; wherein the servomotor-assisted hydro generator, while using the multi-way valve assembly is specified as a unidirectional servomotor-assisted hydro generator and is integrated in the hydraulic circuit.

17. The forging hammer as claimed in claim 16, wherein: the control unit is specified in such a manner that the multi-way valve assembly at least at times during an operating movement of the hydraulic cylinder is actuated such that the hydro pump in terms of fluid technology is connected to a first fluid chamber, in particular the piston chamber, and the hydro generator in terms of fluid technology is connected to a second fluid chamber, in particular the annular chamber, of the hydraulic cylinder, and in that the multi-way valve assembly at least at times during a return movement of the hydraulic cylinder is actuated, such that the hydro pump in terms of fluid technology is connected to the second fluid chamber, and the hydro generator in terms of fluid technology is connected to the first fluid chamber of the hydraulic cylinder; and/or the control unit is specified in such a manner that the hydro pump in sequentially successive, in particular directly successive, portions of an operating cycle of the hydraulic cylinder is connected alternatingly to a, or the, first fluid chamber, respectively, and to the second fluid chamber of the hydraulic cylinder, wherein optionally the hydro generator in a corresponding manner is connected alternatingly to the second fluid chamber and to the first fluid chamber.

18. The forging hammer as claimed in claim 16, wherein: the multi-way valve assembly comprises a 4/2-way valve or at least four individual hydraulic valves which in terms of fluid technology are interconnected by a bridge layout; wherein the bridge layout optionally is configured as a polygonal layout of four hydraulic valves having interdisposed connection points, furthermore the bridge layout is implemented as a parallel layout of in each case two hydraulic valves switched in series; and/or wherein the hydraulic circuit comprises a plurality of hydro pumps that in terms of fluid technology are switched in parallel and/or the hydraulic circuit comprises a plurality of hydro generators that in terms of fluid technology are switched in parallel.

19. The forging hammer as claimed in claim 17, wherein: the hydraulic circuit comprises at least one suction valve which in terms of fluid technology is connected to a suction source, on the one hand, and to at least one fluid chamber of the hydraulic cylinder, in particular to the piston chamber and/or the annular chamber, on the other hand; and/or the coupling of the suction valve in terms of fluid technology is optionally configured in such a manner that a negative pressure that is created in the at least one fluid chamber in the operation of the hydraulic cylinder, in particular of the differential cylinder, is equalizable by suctioning hydraulic fluid by way of the suction valve.

20. The forging hammer as claimed in claim 16, wherein: the control unit is specified for controlling the rotational speed of the pump of the hydro pump in such a manner that the latter during the operation is operated at least at a minimum rotational speed (Dmin) that is unequal to zero, wherein the rotational speed of the pump in an operating range of an operating cycle of the hydraulic cylinder initially is preferably increased from the minimum rotational speed (Dmin) to a maximum rotational speed (Dmax) and subsequently is decreased from the maximum rotational speed (Dmax) to the minimum rotational speed (Dmin); the control unit optionally is specified in such a manner that the hydraulic pump during a plurality of directly successive operating cycles is at all times operated at least at the minimum rotational speed (Dmin), wherein furthermore optionally the control unit is specified in such a manner that the hydraulic pump initially is activated at the minimum rotational speed (Dmin) and subsequently the rotational speed of the pump in an operating range of an operating cycle of the hydraulic cylinder initially is increased from the minimum rotational speed (Dmin) to a maximum rotational speed (Dmax), and furthermore optionally in a subsequent operating portion the rotational speed of the pump is decreased from the maximum rotational speed (Dmax) to the minimum rotational speed (Dmin), in particular in such a manner that the minimum rotational speed (Dmin) is reached at a reversal point of the hydraulic cylinder, wherein furthermore optionally the increase in the rotational speed of the pump of the hydraulic pump is performed so as to correspond to a linear function of time; and/or the control unit is specified in such a manner that when a predefined terminal speed of the striking tool is reached the rotational speed of the pump of the hydraulic pump is decreased when reaching the maximum rotational speed (Dmax) such that the predefined terminal speed under the influence of the hydraulic forces prevalent in the hydraulic circuit and optionally under the force of gravity that acts on the striking tool is reached at or shortly or directly ahead of the reversal point or forming point, or at or shortly or directly ahead of the reversal point of the forming point, wherein optionally for setting the terminal speed the hydro generator is operated as a hydraulic brake in order for the hydraulic piston to be actively decelerated.

21. The forging hammer as claimed in claim 16, wherein: the control unit is configured and specified for controlling the hydro pump in such a manner that a maximum advancing speed of the differential cylinder is in the range between 1.0 to 6 m/s, and/or the control unit is specified in such a manner that an initial point for starting a forming or forging procedure is set so as to depend on a respective terminal speed required depending on the height of the workpiece to be formed, measured in the movement direction of the hydraulic piston; the control unit is specified in such a manner that the path traveled by the striking tool during a forging cycle is minimal, and/or wherein the control unit is specified in such a manner that a striking energy of a last-performed stroke is used for calculating the starting position of the hydraulic piston based on a subsequently required striking energy, wherein the starting position optionally is set so as to depend on the respective height of the workpiece to be formed; and/or the control unit is specified in such a manner that a position, in particular the initial position, of the hydraulic piston is determined at the commencement of or at a defined point in time during a forming or forging cycle and is used as a calculation basis for determining an initial position of the hydraulic piston and/or operating parameters for controlling the movements of the hydraulic piston for a temporally successive forming or forging procedure.

22. The forging hammer as claimed in claim 16, further comprising an energy accumulator which for the purpose of feeding electrical energy that is generated by the hydro generator is connected to the hydro generator.

23. A method for controlling an operating cycle of a forging hammer, comprising: driving a hydraulic cylinder, in particular the differential cylinder, that is coupled to a striking tool by the supply of hydraulic fluid by way of a servomotor-assisted hydro pump of a hydraulic linear drive, said hydro pump in terms of fluid technology being coupled to a hydraulic circuit, and by way of a multi-way valve assembly that in terms of fluid technology is disposed upstream of said hydraulic cylinder; directing hydraulic fluid that herein flows from the differential cylinder by way of the multi-way valve assembly to a servomotor-assisted hydro generator that in terms of fluid technology is disposed downstream in the hydraulic circuit of the multi-way valve assembly; and operating the servomotor-assisted hydro generator while using the multi-way valve assembly as a unidirectional servomotor-assisted hydro generator.

24. A method for controlling an operating cycle of a forging hammer, comprising: driving a hydraulic cylinder, in particular the differential cylinder, that is coupled to a striking tool by the supply of hydraulic fluid by way of a servomotor-assisted hydro pump of a hydraulic linear drive, said hydro pump in terms of fluid technology being coupled to a hydraulic circuit, and by way of a multi-way valve assembly that in terms of fluid technology is disposed upstream of said hydraulic cylinder; directing hydraulic fluid that herein flows from the differential cylinder by way of the multi-way valve assembly to a servomotor-assisted hydro generator that in terms of fluid technology is disposed downstream in the hydraulic circuit of the multi-way valve assembly operating the hydro pump while using the multi-way valve assembly as a unidirectional servomotor-assisted hydro pump; wherein, so as to coincide with reaching a or the first reversal point (U1) that is assigned to a forming region of the forging hammer, or when reaching the one predefined speed of the ram, the method further comprises actuating the multi-way valve assembly in such a manner that elastic energy that is stored, generated and/or created in the hydraulic system of the forging hammer by decompressing the hydraulic fluid or the hydraulic system is converted to electric energy by way of the hydro generator.

25. The method as claimed in claim 24, further comprising: actuating the multi-way valve assembly at least at times during an operating movement of the hydraulic cylinder such that: the hydro pump in terms of fluid technology is connected to a first fluid chamber, in particular the piston chamber, and the hydro generator in terms of fluid technology is connected to a second fluid chamber, in particular the annular chamber, of the hydraulic cylinder, and the multi-way valve assembly at least at times during a return movement of the hydraulic cylinder is actuated such that the hydro pump in terms of fluid technology is connected to the second fluid chamber, and the hydro generator in terms of fluid technology is connected to the first fluid chamber of the hydraulic cylinder, and/or specifying the control unit in such a manner that the hydro pump in sequentially successive, in particular directly successive, portions of an operating cycle of the hydraulic cylinder is connected alternatingly to a first fluid chamber, respectively, and to the second fluid chamber of the hydraulic cylinder, wherein the hydro generator in a corresponding manner optionally is connected alternatingly to the second fluid chamber and to the first fluid chamber.

26. The method as claimed in in claim 24, further comprising: Controlling the hydro pump in such a manner by the control unit that the hydro pump during the operation is operated at least at a minimum rotational speed (Dmin) that is unequal to zero, wherein the rotational speed of the pump in an operating portion of an operating cycle of the differential cylinder initially is: preferably increased from the minimum rotational speed (Dmin) to a maximum rotational speed (Dmax), and subsequently decreased from the maximum rotational speed (Dmax) to the minimum rotational speed (Dmin), and wherein the rotational speed of the pump is preferably set or adjusted to the minimum rotational speed (Dmin) during a return portion of the operating cycle.

27. The method as claimed in claim 24, wherein: the rotational speed of the pump of the hydro pump for accelerating a piston of the hydraulic cylinder in the direction of a first reversal point (U1) that is assigned to a forming region of the forging hammer is increased, in particular in a linear correlation with time from a, or the, respectively, minimum rotational speed (Dmin) to a, or the, respectively, maximum rotational speed (Dmax) in such a manner that the maximum rotational speed (Dmax) is reached ahead of a first reversal point (U1) of the hydraulic cylinder that is assigned to the forming region being reached; the rotational speed of the pump of the hydro pump after reaching the maximum rotational speed (Dmax) is preferably decreased in such a manner, in particular in a linear correlation with time, that the minimum rotational speed (Dmin) is reached as or when the first reversal point (U1) is reached, wherein the hydraulic pump at all times during a plurality of directly successive operating cycles is operated at the minimum rotational speed (Dmin); furthermore optionally the hydraulic pump initially is activated at least at the minimum rotational speed (Dmin), and the rotational speed of the pump subsequently in an operating range of an operating cycle of the hydraulic cylinder is increased initially from the minimum rotational speed (Dmin) to a maximum rotational speed (Dmax); and furthermore optionally in a subsequent operating portion the rotational speed of the pump is decreased from the maximum rotational speed (Dmax) to the minimum rotational speed (Dmin), in particular in such a manner that the minimum rotational speed (Dmin) is reached at a reversal point of the hydraulic cylinder; furthermore optionally when a predefined terminal speed of the striking tool is reached the rotational speed of the pump of the hydraulic pump is decreased when reaching the maximum rotational speed (Dmax) such that the predefined terminal speed under the influence of the hydraulic forces prevalent in the hydraulic circuit and optionally under the force of gravity that acts on the striking tool is reached at or shortly or directly ahead of the reversal point or forming point, or at or shortly or directly ahead of the reversal point of the forming point, wherein optionally for setting the terminal speed the hydro generator is operated as a hydraulic brake in order for the hydraulic piston to be actively decelerated.

13. The method as claimed in claim 24, wherein: so as to coincide with reaching a or the first reversal point (U1) that is assigned to a forming region of the forging hammer, or when reaching the one predefined speed of the ram, the multi-way valve assembly is actuated in such a manner that a pressure output of the hydro pump in terms of fluid technology is connected to a second fluid chamber of the hydraulic cylinder, in particular to the annular chamber of the differential cylinder, and a pressure input of the hydro generator in terms of fluid technology is connected to a first fluid chamber of the hydraulic cylinder, in particular the piston chamber of the differential cylinder.

28. The method as claimed in claim 27, wherein: a negative pressure in the second fluid chamber, in particular in the annular chamber, that is caused by a rebound at the first reversal point (U1) is equalized by a suction valve that in terms of fluid technology is connected to the second fluid chamber, on the one hand, and to a hydraulic container, on the other hand; and an elastic energy that is generated in the hydraulic circuit by the rebound is preferably converted by the hydro generator to electric energy by decompression, and is preferably stored in an intermediate accumulator.

29. The method as claimed in claim 24, wherein: so as to coincide with reaching a second reversal point (U2) of the hydraulic cylinder that faces away from the forming region of the forging hammer, the multi-way valve assembly is actuated in such a manner that a pressure output of the hydro pump in terms of fluid technology is connected to a first fluid chamber of the hydraulic cylinder, in particular to the piston chamber of the differential cylinder; and a pressure input of the hydro generator in terms of fluid technology is connected to a second fluid chamber of the hydraulic cylinder, in particular to the annular chamber of the differential cylinder.

30. The method as claimed in claim 24, wherein: an initial point for starting a forming or forging procedure is set so as to depend on a respective terminal speed required depending on the height of the workpiece to be formed, measured in the movement direction of the hydraulic piston; the path traveled by the striking tool during a forging cycle is minimal.

31. A method for controlling a forging hammer that comprises a striking tool, a hydraulic linear drive coupled to the striking tool and configured for driving the striking tool, a hydraulic circuit comprising a servomotor-assisted hydro pump, a hydraulic cylinder, in particular a differential cylinder, which by way of a multi-way valve assembly in terms of fluid technology is disposed downstream of the hydro pump, a servomotor-assisted hydro generator which by way of the multi-way valve assembly in terms of fluid technology is disposed downstream of the hydraulic cylinder; and a control unit which is conceived for at least controlling the hydro pump, the hydro generator, and the multi-way valve assembly, the method comprising: driving a hydraulic cylinder, in particular the differential cylinder, that is coupled to a striking tool by the supply of hydraulic fluid by way of a servomotor-assisted hydro pump of a hydraulic linear drive, said hydro pump in terms of fluid technology being coupled to a hydraulic circuit, and by way of a multi-way valve assembly that in terms of fluid technology is disposed upstream of said hydraulic cylinder; directing hydraulic fluid that herein flows from the differential cylinder by way of the multi-way valve assembly to a servomotor-assisted hydro generator that in terms of fluid technology is disposed downstream in the hydraulic circuit of the multi-way valve assembly; operating the servomotor-assisted hydro generator while using the multi-way valve assembly as a unidirectional servomotor-assisted hydro generator via a plurality of cycles; and operating the hydro pump across the plurality of operating cycles at least at a minimum rotational speed that is unequal to zero.

32. The method as claimed in claim 31, wherein: secondary energy that is generated by the hydro generator in one operating cycle in a subsequent operating cycle is supplied to the forging hammer, and/or a striking energy of a last-performed stroke is used for calculating the starting position of the hydraulic piston based on a subsequently required striking energy, and/or a position, in particular the initial position, of the hydraulic piston is determined at the commencement of or at a defined point in time during a forming or forging cycle and is used as a calculation basis for determining an initial position of the hydraulic piston and/or operating parameters for controlling the movements of the hydraulic piston for a temporally successive forming or forging procedure.

Description

[0088] Exemplary embodiments of the invention will be described in more detail hereunder by means of the appended figures in which:

[0089] FIG. 1 shows a schematic illustration of the construction of a forging hammer that is configured according to one design embodiment of the invention;

[0090] FIG. 2 shows the forging hammer as per FIG. 1 in a first operating state;

[0091] FIG. 3 shows the forging hammer as per FIG. 1 in a second operating state;

[0092] FIG. 4 shows the forging hammer as per FIG. 1 in a third operating state; and

[0093] FIG. 5 shows an operating diagram relating to the operation and control variables of the forging hammer.

[0094] FIG. 1 shows a schematic illustration of the construction of a downstroke forging hammer 1 that is configured according to one design embodiment of the invention.

[0095] Components of the forging hammer 1 will be described in more detail hereunder by means of FIG. 1, wherein the functioning and the operating mode of the forging hammer 1 will be explained in more detail in particular in the context of FIGS. 2 to 5.

[0096] The forging hammer 1 comprises a frame (not illustrated) on which a differential cylinder 2 is secured. Furthermore, a lower die 3 having a lower tool 4 that is releasably attached to the former is fastened to the frame.

[0097] A piston rod 7 which extends unilaterally from the piston 6 is attached to the piston 6 which is guided so as to be longitudinally displaceable in a cylinder tube 5 of the differential cylinder 2.

[0098] An upper die which is configured as a ram 8, that is to say as a forging ram, is fastened to an end of the piston rod 7 that is remote from the piston 6, said upper die being able to be moved in the longitudinal direction of the cylinder tube 5, in a reciprocating manner so as to coincide with the piston 6.

[0099] The degree of freedom of movement of the piston 6, or of the ram 8, respectively, is schematically illustrated in FIG. 1 by means of a double arrow. The forging hammer 1 in the present case is configured as a vertical forging hammer, which is to mean that a movement of the ram 8, or of an upper tool 9 releasably attached to said ram 8, respectively, in the orderly operating state is performed in the vertical direction from top to bottom and vice versa.

[0100] The forging hammer 1 in the example of FIG. 1 is shown in an operating state in which the upper tool 9 bears on the lower tool 4, so as to correspond to a first reversal point U1 of the ram 8, or of the upper tool 9, respectively.

[0101] The forging hammer 1 has a hydraulic circuit that comprises the differential cylinder 2, said hydraulic circuit having one or, depending on requirements, a plurality of servomotor-assisted hydro pumps 27, the latter each comprising a hydraulic pump 11 that is controlled by way of a servomotor 10, the pressure side 12 of said hydraulic pump 11 in terms of fluid technology being connected to a 4/2-way valve 13, and the suction side 14 of said hydraulic pump 11 in terms of fluid technology being connected to a hydraulic tank 15.

[0102] The hydraulic circuit furthermore comprises a hydro generator 16, the input side 17 of the latter in terms of fluid technology being connected to the multi-way valve 13, and the output side 18 of said hydro generator 16 in terms of fluid technology being connected to the hydraulic tank 15.

[0103] The forming machine 1 furthermore comprises a control unit 19 which is configured and provided with corresponding control lines such that the components of the forging hammer 1, in particular the multi-way valve 13, the hydro pump 27, and the hydro generator 16, and optionally further components, can be controlled.

[0104] The control unit 19 can be designed so as to have various sensors for detecting operating parameters of the forging hammer 1. For example, the forging hammer 1 can have one or a plurality of pressure sensors 20 by way of which a pressure which is prevalent in a piston chamber 21 of the differential cylinder 2 and/or a pressure which is prevalent in an annular chamber 22 of the differential cylinder 2 can be detected in the operation of the forging hammer 1, for example, said detected pressure being able to be used, for example, by the control unit 19 for controlling the forging hammer 1, in particular the differential cylinder 2 and/or the hydro pump 27 and/or the hydro generator 16.

[0105] The hydro generator 16 comprises one or, depending on the requirements, a plurality of hydro motors 28 and a servo generator 29, that is to say a generatively operated servomotor, that in terms of drive technology is coupled to the hydro motor 28.

[0106] The hydro pump 27 and the hydro generator 16 can be controlled by means of the servomotor 10 and of the servo generator 29, and for this purpose are connected to the control unit 19 by way of respective control lines. In particular, the hydro pump 27 and the hydro generator can be controlled in terms of rotational speed and/or torque, for example in such a manner that a for setting and/or achieving a pre-defined or desired terminal speed of the ram 9 is achieved. In particular, the hydro pump 27 and the hydro generator 16 can be controlled such that the ram 9 or the piston 6 follows a pre-defined motion sequence, wherein hydro pump 27 and hydro generator 16 make available the hydraulic drive output or brake output that is required in each case.

[0107] The forging hammer 1 can furthermore comprise a position and/or speed sensor 23 by way of which a position and/or speed of the ram 8, or of the piston 6, respectively, can be determined by the control unit 19, wherein respective position and/or speed data can be used for controlling the hydraulic circuit, in particular the hydro pump 27 and/or the hydro generator 16 and/or the multi-way valve 13, for example for controlling or setting a respective desired terminal speed or impact speed of the differential cylinder 2.

[0108] The forging hammer 1 shown in the context of the figures furthermore comprises an energy accumulator 24 in which secondary energy, for example in the form of electric energy, that has been generated by the hydro generator 16, for example by converting hydraulic energy, in particular elastic energy, from the hydraulic circuit, can be stored. The energy accumulator 24 can be connected to the control unit 19 for controlling the charging and discharging of the former. In particular, the energy accumulator 24 and the associated controls can be mutually adapted such that energy that has been recovered from one or from a plurality of preceding operating cycles of the forging hammer 1 can be used or accessed for operating the forging hammer 1, for example the hydro pump 27, in subsequent operating cycles.

[0109] The piston chamber 21 and the annular chamber 22 of the differential cylinder 2, in order for any negative pressures that can potentially arise in the hydraulic system to be equalized, in terms of fluid technology are connected to the hydraulic tank 15 by way of suction valves 25 in such a manner that hydraulic fluid 30 in the case of any negative pressure can be suctioned from the hydraulic tank 15 by way of the suction valves 25 and can thus be introduced into the hydraulic system.

[0110] In particular, the piston chamber 21 and the annular chamber 22 in terms of fluid technology can each be connected to the hydraulic tank 15 or to a hydraulic fluid source, by way of one suction valve 25 such that hydraulic fluid in the case of any negative pressure is suctioned into the piston chamber 21 or the annular chamber 22 by way of a suction effect that is caused by the negative pressure.

[0111] The suction valves 25 can be spring-loaded non-return valves, for example, or other equivalent valves, which permit only a unidirectional flow of hydraulic fluid in the direction from the hydraulic tank 15 to the piston chamber 21 or the annular chamber 22, but block the flow in the opposite direction.

[0112] An exemplary operating mode of the forging hammer 1 based on the components described above will be described hereunder by means of FIGS. 2 to 5 which show the forging hammer 1 in various operating states.

[0113] FIG. 2 shows the forging hammer 1 in an operating state in which the hydro pump 27 and the multi-way valve 13 are controlled by the control unit 19 in such a manner that the piston 6 of the differential cylinder 2 for the purpose of machining a workpiece 26 is accelerated or moved in the direction of the lower tool 4.

[0114] The multi-way valve 13 in the present exemplary embodiment is embodied as a 4/2-way valve, and in the operating state shown in FIG. 1 is switched such that a first connector A1 which in terms of fluid technology is connected to the pressure side 12 of the hydraulic pump 11 is switched so as to communicate with a second connector A2 which in terms of fluid technology is connected to the piston chamber 21. In this way, hydraulic fluid 30 by way of controlling the servomotor 10 in a corresponding manner can be pumped by the hydraulic pump 11 from the hydraulic tank 15 into the piston chamber 21 in order for the stroke of the piston 6 to thus be enlarged and for a hydraulic acceleration force to be transmitted to the piston 6.

[0115] Furthermore in the operating state shown in FIG. 1, in which the piston 6 is accelerated or moved in the direction of the lower tool 4, respectively, a third connector A3 of the multi-way valve 13 in terms of fluid technology is connected to the annular chamber 22 and switched so as to communicate with a fourth connector A4 of the multi-way valve 13, said fourth connector A4 in terms of fluid technology being connected to the hydro generator 16, more specifically to the input side 17 of the hydro motor 28.

[0116] Since the forging hammer 1 in the present example is configured as a downstroke forging hammer 1 having an overhead differential cylinder 2, apart from the hydraulic forces that are generated by the hydro pump 27 and by the hydro generator 16, the weight forces of the moving mass, in particular of the ram 8, the piston rod 7, the piston 6, the upper tool 9, etc., also contribute toward the acceleration of the ram 8 in the direction of the lower tool 4.

[0117] In the case of an upstroke forging hammer or an upstroke forging ram, to which the present invention can likewise be applied, the weight forces act counter to the hydraulic force in the acceleration of the ram in the direction of the workpiece to be machined, this in terms of control technology likewise being able to be detected by the hydraulic system proposed herein. In the case of a combination of a downstroke and an upstroke forging hammer, both the downstroke forging hammer and the upstroke forging hammer can be controlled by the method proposed herein and be of a respective construction.

[0118] Reverting to the state shown in FIG. 1, it is furthermore explained that the ram 8 in the operating state shown is impinged with hydraulic fluid 30 by the hydro pump 27 in such a manner, and the hydro generator 16, to the extent required, scavenges hydraulic energy from the hydraulic system and acts as a hydraulic brake to such an extent, that the upper tool 9 when impacting the workpiece 29 to be machined has a respective desired impact speed or terminal speed, respectively, and a respective desired or pre-defined, respectively, forming energy can be imparted to the workpiece.

[0119] In order for the acceleration of the ram 8 to be controlled and for the speed of the ram 8 to be set, the control unit 19 can evaluate one or a plurality of position and/or speed sensors 23, and by means of the data obtained on account thereof, for example by means of the determined actual speed of the ram 8, or in a corresponding manner of the upper tool 9 or of the piston 6, can control the hydro pump 28 and/or the hydro generator 16 in such a manner that the desired terminal speed is reached.

[0120] During the movement of the ram 8 or of the piston 6, respectively, in the direction of the workpiece 26 or of the lower tool 4, hydraulic fluid 30, in a manner corresponding to the volumetric flow that is generated by the hydraulic pump 11, flows into the piston chamber 21. At the same time, hydraulic fluid 30 that is located in the annular chamber 22 is displaced from the annular chamber 22, said hydraulic fluid 30 being returned into the hydraulic tank 15 by way of the multi-way valve 13 and of the hydro generator 16.

[0121] In that the hydro generator 16 is disposed in the return line, elastic energy that is stored in the hydraulic system, for example, can be scavenged from the hydraulic system and be converted to electric energy. The electric energy in turn can be temporarily stored in the energy accumulator and in subsequent operating cycles or else directly be provided to the forging hammer 1. Elastic energy that is stored in the hydraulic system can be released by decompressing the hydraulic fluid 30, for example.

[0122] Furthermore, hydraulic energy can be scavenged from the hydraulic circuit by controlling the hydro generator 16, that is the servo generator 29, in a corresponding manner in that, for example, the torque of the servo generator 29 is increased such that kinetic energy of the hydraulic fluid flowing through the hydro motor 28 is converted to electric energy. The latter leads to a braking effect, such that the moving mass, in particular the piston 6, the ram 8, etc., can be decelerated in a targeted manner.

[0123] This means that the hydro generator 16 in the hydraulic system proposed herein can be operated as hydro-fluidic brake for generating a braking effect on the moving mass, in particular on the ram 8. For example, the hydro-fluidic brake effect can be employed for the purpose of setting a respective required terminal speed in the movement in the direction of the first reversal point U1, and/or for decelerating the moving mass in the movement in the direction of the second reversal point U2, for example in the region of the upper second reversal point, while controlling the hydro generator 16 in a corresponding manner.

[0124] By way of the solution proposed herein, the hydro pump 27 and the hydro generator 16 are operable in a substantially simultaneous manner at any time during the entire operating cycle, wherein the hydro pump 27 enables a (positive) acceleration force to be generated, and the hydro generator 16 enables a braking force acting counter to the former to be generated. In particular on account thereof, comparatively accurate and precise controlling of the motion sequence of, for example, the ram 9, substantially during the entire operating cycle of the forging hammer 1, that is to say for example apart from temporal portions in which the multi-way valve 13 is being switched, can be achieved.

[0125] Any potential negative pressures that arise in the hydraulic system, that is to say in the piston-chamber side of the hydraulic system, in the case of the forging hammer 1 shown can be equalized in particular in that hydraulic fluid 30 can flow by way of the suction valve 25 that in terms of fluid technology is connected to the piston chamber 21 and to the hydraulic tank 15.

[0126] Negative pressures in the piston-chamber side part of the hydraulic system can arise, for example, when the volumetric flow of hydraulic fluid 30 that is generated by the hydro pump 27 during the acceleration of the ram 8 lags behind the volumetric variation that is caused by the enlargement of the piston chamber 21. The latter can arise, for example, when the volumetric variation of the piston chamber 21 that is caused by the accelerating effect of gravity is greater than the volumetric flow of hydraulic fluid 30 that is provided by the hydro pump 27.

[0127] For example, the volumetric flow of the hydraulic pump can be reduced following the expiry of a pre-defined acceleration period or phase, that is to say at or following the end of the hydraulic filling period of the piston, such that the piston can reach the respective pre-defined terminal speed.

[0128] In exemplary operating sequences, the time required for moving the ram 8 from a second reversal point U2 of the piston 6 or of the ram 8 that is remote from the lower tool 4 to the first reversal point U1 can be approximately 200 ms (milliseconds).

[0129] With a view to the quite significant masses to be moved which in the case of forging hammers can be up to several tons, and with a view to the comparatively high terminal speeds, correspondingly high hydraulic outputs which moreover have to be tuned and controlled in a comparatively short time and moreover with great accuracy are required.

[0130] Moreover, comparatively high volumetric flows of hydraulic fluid and comparatively high flow velocities arise in the hydraulic circuit in the case of forging hammers, said volumetric flows and flow velocities having to be controlled in a corresponding manner in order for a safe and reliable operation to be ensured.

[0131] The objects and challenges mentioned above in particular can be overcome by way of the forming machines proposed and described herein, in particular by way of the hydraulic system proposed herein.

[0132] FIG. 3 shows the forging hammer 1 in an operating state in which the ram 8 is at the first reversal point U1, that is to say presently the lower reversal point. In that the ram 8, in particular the upper tool 9, impacts the workpiece 26, the respective moving mass comprising in particular the mass of the ram 8, of the upper tool 9, of the piston 6, of the piston rod 7, is decelerated, wherein the dynamic energy is introduced as forming energy into the workpiece 26 in order for the latter to be formed.

[0133] It is possible for the terminal speed of the ram 8 to be set in a comparatively accurate manner in particular by way of the hydraulic system proposed herein, having hydro pump 27 and hydro generator 16 that are operable simultaneously during the operating cycle, such that advantageous forging results can be obtained.

[0134] In the region of the impact of the upper tool 9 on the workpiece 26, or directly following said impact, a rebound which in particular depending on the material of the workpiece is more or less pronounced can arise on the decelerated mass, said rebound entailing an acceleration in a direction that points away from the lower tool 4. The impact and the rebound can take place in a temporal period of 0.5 ms to 20 ms, for example.

[0135] On account of the rebound, the piston 6 in particular is moved abruptly from the first reversal point U1 in the direction of the second reversal point U2. On account thereof, a displacement effect is created in the piston chamber 21 in respect of the hydraulic fluid that is located in the latter, on the one hand, and a negative pressure and, in a manner corresponding thereto, a suction effect are created in the annular chamber 22, or in the annular chamber 22 being created, respectively, on the other hand.

[0136] In order to take account of the changed conditions in the hydraulic system in the region of the impact and/or of the first reversal point, the multi-way valve 13 is controlled in a corresponding manner by the control unit 19, in particular in such a manner that the third connector A3 in terms of fluid technology is connected to the first connector A1, and that the second connector A2 in terms of fluid technology is connected to the fourth connector A4 of the multi-way valve 13. On account thereof, the piston chamber 21 in terms of fluid technology is connected to the hydro generator 16, and the annular chamber 22 in terms of fluid technology is connected to the pressure side 12 of the hydraulic pump 11. A respective switching reversal of the multi-way valve 23 in temporal terms can also be performed ahead of the first reversal point U1, for example at the point in time at which the ram 9 is at the desired terminal speed. For example, switching of the multi-way valve 23 can be performed at a point in time at which the respective desired terminal speed is reached, and any optionally required deceleration, or a deceleration procedure, of the piston 6 or of the ram 8 has been completed. The deceleration procedure can be performed, for example, in the final portion of the movement of the ram 8 in the direction of the forming region, or in the direction of the workpiece 26, respectively. The end of the deceleration procedure in temporal terms can be ahead of the point in time of impact of the ram 8 in the operating region. To this extent, switching of the multi-way valve 23 in temporal terms can be performed in particular shortly ahead of the point in time of impact, in particular in such a manner that the respective required switching position of the multi-way valve 23 is present at least at the point in time of impact.

[0137] In general, controlling of the multi-way valve 23 can be performed in such a manner that control procedures, in particular taking into account any potential system inertia or switching times, are initiated in a temporally advanced manner such that the switched position of the multi-way valve 23 required for a specific point in time is reliably achieved at the respective point in time.

[0138] In the switched position of the multi-way valve 13 that is shown in the operating state of FIG. 4, hydraulic fluid 30 that on account of the displacement effect has been displaced from the piston chamber 21 can be discharged by way of the hydro generator 16 into the hydraulic tank 15. In particular, the elastic energy that has been generated, for example, by the rebound in the hydraulic system and been released by decompressing the hydraulic system can be converted to electric energy by the hydro generator 16, wherein the hydro generator 16 by way of the servo generator 29 is controlled in a corresponding manner such that the former, driven by the hydro motor 28, can convert the elastic energy at least in part to electric energy.

[0139] The electric energy can be stored in the energy accumulator 24 which in electric terms is connected to the servo generator 29, said electric energy being able to be used, for example, for subsequent operating cycles in order for inter alia the hydro pump 27 to be electrically driven.

[0140] Furthermore, on account of the connection in terms of fluid technology between the hydro pump 27 and the annular chamber 22, hydraulic fluid 30 can be supplied to the annular chamber 22, in order for the hydraulic fluid that on account of the movement of the piston in the direction of the second reversal point U2 is required in the annular space 22 to be provided at least in part, or in order for the annular chamber 22 to be supplied with hydraulic fluid 30 so as to correspond at least in part to the movement of the piston 6.

[0141] On account of the comparatively high accelerations that arise in the case of the rebound, it can happen that the volumetric variation of the annular chamber 22 that is caused by the movement of the piston 6 in the direction of the second reversal point U2 is greater than the volumetric flow that is delivered by the hydro pump 27. In this situation, despite the hydro pump 27 being active, a negative pressure, or a suction effect, respectively, can be created on the side of the annular chamber, said negative pressure or suction effect according to the solution proposed herein being able to be equalized by the suction valve 25 on the annular chamber side. The annular chamber 22 on account of the suction valve 25 on the annular chamber side, in terms of fluid technology is connected to the hydraulic tank 15 such that, caused by the suction effect, hydraulic fluid 30 can flow from the hydraulic tank 15 into the annular chamber 22.

[0142] As has already been mentioned, the suction valve or valves 25, respectively, can be configured as non-return valves and offer the potential of absorbing negative-pressure surges in the hydraulic system without total control of the hydraulic system by way of the control unit 19 being required to this end.

[0143] In particular, in order for negative-pressure surges, or negative pressures in general, to be equalized, it is not necessary for the hydro pump 27, for example in the region of the rebound, to be operated at a corresponding increased rotational speed and at a correspondingly higher conveying output. Instead, following switching of the multi-way valve 13 in a manner corresponding to the configuration as per FIG. 4, in which the hydro pump 27 in terms of fluid technology is connected to the annular chamber 22, and the hydro generator 16 in terms of fluid technology is connected to the piston chamber 21, the hydro pump 27 can be operated by the control unit 19 for example at a minimum rotational speed, or a minimum conveying output, respectively, that is required in order for the piston 6, upon the rebound having abated, to be moved at the speed that is required in each case to the second reversal point U2. The control complexity in particular can be reduced in this way.

[0144] The movement of the piston 6 from the first U1 to the second reversal point U2 in exemplary operating cycles can be performed in approximately 500 ms, for example.

[0145] The control unit 19, when reaching the second reversal point U2 or in a temporal period ahead of reaching the latter, can control the hydraulic circuit, in particular the multi-way valve 13 and the hydro pump 27 and the hydro generator 16 in such a manner that the piston 6 is decelarated conjointly with the moving mass connected to the latter. The deceleration procedure in exemplary operating cycles can be performed in a temporal duration of approx. 100 ms, for example.

[0146] The control unit 19, in order for the piston 6 and the mass moved thereby to be decelerated in the region of the second reversal point U2, can actuate the hydro generator 16 in such a manner that hydraulic energy is scavenged by the hydro generator 16 from the hydraulic fluid that flows back from the piston chamber 21, such that the hydro generator 16 acts as a hydro-fluidic brake.

[0147] At the same time, in as far as this has not already happened, the hydro pump 27 can be controlled in such a manner that the quantity conveyed by the latter is or is to be reduced, for example in such a manner that the hydro pump 27 is operated at the minimum rotational speed.

[0148] In the case of a downstroke operated forging hammer, the gravity that in the decelaration acts on the moving mass in a manner corresponding to the figures acts in an additionally decelerating manner in terms of the movement in the direction of the second reversal point U2.

[0149] The hydraulic system, in order to decelerate in the region of the second reversal point U2, optionally using detected sensor-based position and/or speed data of the ram 8, is in any case controlled such that the ram 8 is completely decelerated at the second reversal point U2. It is to be noted only for the sake of completeness that the deceleration of the moving mass at the first reversal point U1 is performed by the forging procedure per se, wherein effects such as the rebound in the case of the first reversal point U1 are however to be absorbed or managed by controlling the hydraulic system in a corresponding manner.

[0150] The control unit 19, following the deceleration at the second reversal point U2, can control the hydraulic system in a manner corresponding to the sequence diagram described earlier in order for a further operating cycle to be carried out. The control unit 19 herein can control the multi-way valve 13 in such a manner that the hydro pump 27, as is shown in FIG. 2, in terms of fluid technology is again connected to the piston chamber 21, and the hydro generator 16 in terms of fluid technology is again connected to the annular chamber 22.

[0151] To the extent that an impact speed that is different from, for instance, that of a preceding operating cycle is required in a subsequent operating cycle, the hydro pump 27 and the hydro generator 16 for setting the defined impact speed can be controlled in a corresponding manner in the acceleration of the moving mass, and optionally in the deceleration of the moving mass.

[0152] It is to be noted here that any modification or variation of the impact speed can be established in a comparatively simple manner by way of the hydraulic system proposed herein and of the switching plan proposed herein of the hydro pump 27, of the multi-way valve 13, and of the hydro generator 16 and of the controller 19 connected thereto. In particular, by way of the system proposed herein, changes in terms of parameters can be reacted to in a comparatively flexible manner by a corresponding variation in terms of control, optionally by additionally evaluating pressure, position, or speed sensors.

[0153] FIG. 5 shows an operating diagram relating to operation and control variables of the forging hammer 1, wherein a total of five curves are illustrated, wherein a first rotational speed curve D1 describes the temporal correlation, or the temporal profile of the rotational speed of the hydraulic pump 11, respectively. A second rotational speed curve D2 describes the temporal correlation, or the temporal profile of the rotational speed of the hydro generator 16, respectively.

[0154] A first torque curve M1 describes the temporal correlation or the temporal profile of the torque of the hydraulic pump 11, respectively, and a second torque curve M2 shows the temporal correlation or the temporal profile of the torque of the hydro generator 16, respectively.

[0155] A movement curve B describes the temporal correlation or the temporal profile of the stroke of the piston 6 or of the ram 8, respectively. According to the movement curve B, the piston moves from the second reversal point U2 to the first reversal point U1, and then back again to the second reversal point U2.

[0156] In the motion sequence as per the movement curve B, shown in an exemplary manner, the piston 6 or the ram 8, respectively, so as to correspond to a start of an operating cycle, at a starting point in time t0 at t=0 is located at the second reversal point U2. The ram 8, or the piston 6, respectively, is accelerated from the second reversal point U2 in the direction of the first reversal point U1, wherein the multi-way valve 13 is controlled in such a manner that the hydro pump 27 in terms of fluid technology is connected to the piston chamber 21. The hydro generator 16 in this operating state, in terms of fluid technology, is connected to the annular chamber 22.

[0157] For acceleration, the pump torque of the hydro pump 27 and thus the output that is transmittable into the hydraulic system is increased in a manner corresponding to a comparatively steep flank, in the present exemplary curve as per FIG. 5 to approximately 1100 Nm.

[0158] As the speed of the ram 8 increases, the torque required for accelerating the ram 9 drops, not least because the gravity of the moving mass contributes toward the acceleration. The ram 8 and the moving mass is accelerated up to a first point in time t1 which is ahead of a second point in time t2 at which the ram 8 reaches the first reversal point U1.

[0159] The rotational speed of the hydro pump 27, in a manner coinciding with the increasing speed of the ram 8 or of the piston 6, respectively, increases from the minimum rotational speed Dmin up to the maximum rotational speed Dmax, in a manner corresponding with the volumetric variation of the piston chamber 21 that is caused by the movement of the piston 6. In the same temporal period between t0 and t1 hydraulic fluid 30 is displaced at an increasing volumetric flow from the annular chamber 21, wherein the rotational speed of the hydro generator 16, that is to say the rotational speed of the hydro motor 28 of the hydro generator 16 increases in a manner so as to coincide with the increasing volumetric flow.

[0160] A setting of the respective terminal speed can optionally be performed in the temporal period between the first point in time t1 and the impact point, the latter corresponding substantially to the second point in time t2 that is assigned to the first reversal point U1, in other words in the temporal period between the end of the acceleration phase and the point in time of impact.

[0161] The multi-way valve 13, in order for the speed to be set, can be switched such that the hydro pump 27 is connected to the annular chamber 22, and the hydro generator 16 is connected to the piston chamber 21. As is shown in an exemplary manner in the diagram, the torque of the hydro generator 16 herein can be increased in the temporal period between t1 and t2, which means in particular that energy is scavenged from the hydraulic fluid that flows into the piston chamber, this ultimately decelerating the volumetric flow to the piston chamber 21, on account of which a braking effect on the ram 9 can be generated. That is to say that the hydro generator 16 in this temporal period acts as a hydro-fluidic brake in order to optionally counteract any further acceleration of the ram 8 upon reaching the terminal speed.

[0162] The rotational speed of the hydro generator 16 at the point in time mentioned between t1 and t2 is approximately constant (cf. curve D2). Ahead of the point in time t1, in the temporal interval between t0 and t1 in the example of FIG. 5, the rotational speed of the hydro generator 16 can be set to, in particular increased to, the rotational speed that is required for the generative operation.

[0163] The torque of the hydro generator 16 (cf. curve M2) increases up to the second point in time t2, which can mean, for example, that the hydro generator 16 in actual fact does scavenge hydraulic energy from the hydraulic system.

[0164] With a view to the profiles of the torque and of the rotational speed of the hydro motor 28 and of the hydro generator 16 that are shown in FIG. 5 and stated in an exemplary manner, it is to be mentioned that the respective actual profile of the curves can deviate so as to depend on the respective hydraulic system. For example, the profile of the rotational speed and/or of the torque can be temporally offset in relation to the points in time t0 to t4, which can be caused, for example, by different mass inertias and/or fluid inertias of the hydraulic fluid and/or of components of the hydraulic system. For example, the increase in the rotational speed of the hydro generator 16 ahead of the point in time t1 to the rotational speed that is required or suitable for the generative operation can also be achieved in a manner other than by the profile shown in FIG. 5. In other words, the rotational speed and the torque of the hydro motor and/or the hydro generator of different forging hammers can deviate from the profile shown in FIG. 5, so as to depend on the respective conception and dimensioning in particular of the hydraulic system.

[0165] At the same time, the hydro pump 27 in the temporal period between t1 and t2 is controlled in such a manner that the rotational speed drops to the minimum rotational speed Dmin, wherein the torque increases upon reaching the terminal speed.

[0166] It should be mentioned herein that the rotational speed and the torque of the hydro pump 27 are set in such a manner that the piston from the second point in time t2 on can be moved at a pre-defined return speed, for example 2 m/s, from the first reversal point U1 in the direction of the second reversal point U2.

[0167] The hydro pump 27 from the second point in time t2 on, in a manner corresponding to the exemplary profile shown in FIG. 5, is operated so as to correspond to the previously set minimum rotational speed Mmin and the respective torque, and the ram 8, or the piston 6, respectively, are moved from the first reversal point U1 to the second reversal point U2. In order for the hydro generator 16 not to act as a hydraulic brake in the return movement and not to act on the hydro pump 27 in a decelerating manner, the torque of the hydro generator 16 after the second temporal period is reduced to zero.

[0168] The rotational speed of the hydro generator 16, that is to say of the hydro motor 28, in this temporal period is the result of in particular the volumetric flow of the hydraulic fluid 30 that is displaced from the piston chamber 21.

[0169] The return movement of the piston 6 from a third point in time t3 on is slowed down in such a manner that the piston 6 conjointly with the moving mass connected therewith is decelerated at the second reversal point U2, and that the operating cycle can be repeated.

[0170] For deceleration, the torque of the hydro generator 16 is increased such that the latter acts as a hydraulic brake for decelerating the mass moving in the direction of the second reversal point U2. In a manner coinciding therewith, the torque of the hydro pump 27 is reduced, this likewise leading to the return movement being slowed down. On account of these measures and of the acting gravity, the moving mass is completely decelerated up to a fourth point in time t4 which defines the end of the operating cycle.

[0171] A further operating cycle which is carried out so as to correspond to the operating cycle described above can follow on from the fourth point in time, wherein upon switching reversal of the multi-way valve 13, the hydro pump 27 is again connected to the piston chamber 21, and the hydro generator 16 is again connected to the annular chamber 22.

[0172] It is demonstrated overall that comparatively accurate controlling of the hydro motor 28 and of the hydro generator 16 is possible by means of the proposed hydraulic system in such a manner that the ram 8 can be controlled so as to correspond to a respective pre-defined motion sequence and movement and speed profile, and any lost energy arising in the hydraulic system can at the same time be converted to useful energy. Comparatively accurate and energy-efficient operating cycles for the differential cylinder 2 and the forging hammer 1 can be implemented by the controller proposed herein and the construction of the hydraulic system of the forging hammer proposed herein.

[0173] A comparatively accurate and reliable setting of the motion sequence and of the speed, in particular of the terminal speed, or the impact speed, respectively, of the ram 9 can be achieved in particular on account of the potential of the simultaneous operation of the hydro pump 27 and of the hydro generator 16.

[0174] Controlling of the arrangement proposed herein, consisting of the hydro pump, the hydro generator, and the multi-way valve, can be relieved and simplified by way of the suction valves 25, for example, which can equalize any states of negative pressure and pressure surges, for example hydraulic shocks to the piston, the hydro pump, the hydro generator, and/or the multi-way valve assembly, in the hydraulic system in a quasi automatic manner. The latter not only has an advantageous effect on the controlling complexity, but a comparatively wear-free operation can also be simultaneously achieved.

LIST OF REFERENCE SIGNS

[0175] 1 Forging hammer [0176] 2 Differential cylinder [0177] 3 Lower die [0178] 4 Lower tool [0179] 5 Cylinder tube [0180] 6 Piston [0181] 7 Piston rod [0182] 8 Ram [0183] 9 Upper tool [0184] 10 Servomotor [0185] 11 Hydraulic pump [0186] 12 Pressure side [0187] 13 Multi-way valve [0188] 14 Suction side [0189] 15 Hydraulic tank [0190] 16 Hydro generator [0191] 17 Input side [0192] 18 Output side [0193] 19 Control unit [0194] 20 Pressure sensor [0195] 21 Piston chamber [0196] 22 Annular chamber [0197] 23 Position or speed sensor [0198] 24 Energy accumulator [0199] 25 Suction valve [0200] 26 Workpiece [0201] 27 Servomotor-assisted hydro pump [0202] 28 Hydro motor [0203] 29 Servo generator [0204] 30 Hydraulic fluid [0205] U1 First reversal point [0206] U2 Second reversal point [0207] A1-A4 First to fourth connectors [0208] D1, D2 Rotational speed curve [0209] M1, M2 Torque curve [0210] B Movement curve [0211] t0 Starting point in time [0212] t1-t4 First to fourth point in time [0213] Dmin Minimum rotational speed [0214] Dmax Maximum rotational speed