2013 Yao Open Jme

Open Journal of Mechanical Engineering, Vol.1 No.
3 (2013) pp 1-16
Available online at http://www.arpub.org/jme/
Optimal Design of Hydraulic System for an Industrial Press

Machine for Performance Improvement and Noise Reduction
*1
Jiafeng Yao, 2 Baochun Lu, 3 Chris Zhang, 4 Michio Sadatomi
1
Kumamoto University, Japan, jiaf.yao@gmail.com
2
Nanjing University of Science & Technology, China, lucnust@sina.com
3
University of Saskatchewan, Canada, chris.zhang@usask.ca
4
Kumamoto University, Japan, sadatomi@mech.kumamoto-u.ac.jp
Abstract
In this paper, we present an optimal design of the hydraulic system for a class of industrial press
machines. Such machines are expected to produce a large pressure on a work-piece and they are driven
by a hydraulic system. Excessive vibration in the period where the press is changed from pressure
holding to pressure relief is a common bottleneck problem with such machines. The vibration is closely
related to the hydraulic system that controls a press head’s movement and is subsequently responsible
for the property of work-pieces. In the present study, we proposed a novel design of the hydraulic circuit
for pressure relief and applied it to a brick press machine and evaluated through simulation by AMESim
software, which showed that the design is effective. Finally, the simulation results were validated in
practical operation, which showed that, the violent vibration was decreased significantly and the noise
level of the new machine is decreased from 80 decibel to 58 decibel.
Keywords: Optimal Design, Hydraulic System, Pressure relief, Simulation, AMESim
I. Introduction
A hydraulic press is a mechanical machine used for lifting or compressing large items. The force is
generated through the use of hydraulics to increase the power of a standard mechanical level. This type
of machine is typically found in a manufacturing environment.
Invented in 1795 by Joseph Bramah, the hydraulic press is also known as the Bramah press. He used his
knowledge of fluid mechanics and motion to develop this device. This invention significantly increased
the compression power available, expanding the product groups and options available to other inventors.
By applying hydraulics to a press, an entire class of machines was invented. There is a wide range of
different hydraulic press machines, ranging from small table top units for hobbyists to huge machines
used to create metal parts.
The primary concept used to provide power to the hydraulic press is that the level of pressure in a closed
system is constant. This type of press has pistons with a fluid inside that is displaced by the pistons'
inward movement. The fluid forces its way back into the space by moving the piston outward. The
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Open Journal of Mechanical Engineering, Vol.1 No.3 (2013) pp 1-16
additional power is created through the movement of the fluid, which is confined to the system.
In this paper, we present an optimal design of the hydraulic system for a class of industrial press
machines. Such machines are expected to produce a large pressure on a work-piece and they are driven
by a hydraulic system. Excessive vibration in the period where press is changed from pressure holding
to pressure relief is a common bottleneck problem. It is noted that this period will be called ‘pressure
switching” period in this paper hereafter. The vibrations are closely related to the hydraulic system for
control of a press head’s movement as well as the property of work-pieces.
One of the existing solution principles is to control the movement of the press head to produce a proper
pressure profile. For instance, two methods based on this principle are available in [1, 2]. However, from
our experience in designing and operating some press machine in practice with these two methods, it is
found that they may not be satisfactory. For instance, a particular brick press machine has a noise level
up to 80 decibels [3]. Fig. 1 shows its pressure profile during the pressure switching period.
As it is shown in Fig. 1, there are four periods during the working process. There is a sharp drop during
the period d-e (the 6th second), and this means that when the press head moves back, the pressure in the
chamber drops abruptly, which is a source of impact vibration.
The objective of this paper is to present a novel redesign of the hydraulic control system to reduce the
vibration significantly. Since the pressure change of the hydraulic system is difficult to measure, we
developed a simulation method by AMESim software to find out the source of hydraulic impact and
validate the pressure relief effect of the new method. The evaluation criterion of the simulation results
are the level of noise (actually, noise is come from the violent vibration of the hydraulic impact). To
illustrate and validate the proposed design, we take a particular type of brick press machine as an
example.
Figure 1. The pressure profile in the pressure switching period (a-b: press head down period; b-c:
pressing period; c-d: pressing holding period; d-e: pressing relief period; Note: 1 MP = 10 Bar.
This paper is organized as follows. Firstly, the proposed redesign in the context of press machine is
described, followed by modeling and simulation of both the new design and old design. After that,
results are presented and discussed. Finally, there is a discussion of conclusion, limitation and future
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work.
II. Optimal design of the hydraulic circuit system for press machine
A. The generic operation of press machine
A working process of a manufacturing system such as brick product or powder metallurgy is described
as follows (Fig. 2): (1) press head is in contact with the work-piece (Fig. 2a), (2) press head is further
down to deform the work-piece (Fig. 2b), (3) press head holds up with the work-piece (Fig. 2c), (4)
press head is slightly up (Fig. 2d), and (5) press head is up (Fig. 2e). The performance of a press
machine, in particular vibration and impact behavior is closely related to the pressure profile (Fig. 1) and
the property of the work-piece.
Figure 2. Generic operation of press head.
The generic structure of a machine system is shown in Fig. 3. When Pu < Pl, press head is up; otherwise
press head is down. A control system is associated with the fluids in the upper chamber and the lower
chamber. The fluids are represented by their flow rates (vu, vl), respectively. For the press machine,
hydraulic systems are commonly employed to implement the control system, because they can generate
high power with a high degree of compliance when the head interacts with the work-piece.
Figure 3. Generic structure of press.
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B. Proposed design for pressure relief of hydraulic system
Two principles are widely used in the hydraulic control system for pressure relief.
The first principle (Principle 1) is to release fluid from the upper chamber gradually and continuously
using a throttle valve, and Fig. 4 shows a conceptual design which follows the first principle. In the
hydraulic system, during the press action, high pressure is generated in the hydraulic cylinder. After that,
the oil could run through the throttle valve to relieve the impact during the pressure change. This method
is easy to control but the potential disadvantage is that pressure relief from the upper chamber may be
too slow such that the pressure in the lower chamber may be accumulated to a level larger than the
pressure in the upper chamber, leading to the head going up quickly and causing vibration [4].
Figure 4. Pressure relief method with a throttle valve.
The second principle (Principle 2) is to release the fluid by a pressure valve group, and Fig. 5 shows a
conceptual design which follows the second principle. The pressure valve group can relieve the pressure
gradually because when the pressure is high, the oil can flow through the two valves in succession.
The main problem is, pressure relief from the upper chamber is not smooth, i.e., the pressure of the
upper chamber decreases sharply and also brings about a little impact [1].
In this paper, we proposed a new principle (Principle 3), which combined Principle 1 and 2 due to their
complementary behavior, as shown in Fig. 6. The combination of the two was such that the second
principle provides a main regulation of fluid while the first principle provides a varying regulation. In
particular, a throttle valve and a check valve were added in the design. The throttle valve was used to
adjust the flow rate according to different working conditions and the check valve was to prevent the
backlash of the oil.
4
Figure 5. Pressure relief method with a pressure valve group.
Figure 6. Proposed principle for pressure relief (P: Oil Entrance Port; T: Outlet Port; C: Controlling
Port).
A conceptual design for the proposed principle is shown in Fig. 7. A remote control port of relief valve
(valve 2) is connected with P2 (P2 has a low pressure, as it is connected to a relieving valve), through a
throttle valve (valve 3) and a check valve (valve 4). The opening velocity of relief valve (valve 2) can
thus be adjusted by regulating the port of valve 3. It is also noted that the relieving velocity of the cavity
can be adjusted correspondingly. The pre-setting pressure of valve 2 should be greater than the working
pressure; in this way, valve 2 can also serve as a safety valve. This pressure-relieving loop is particularly
designed for the dual-pump and double-circuit hydraulic system which suits a large flow-rate brick press
machine.
5
Figure 7. Conceptual design of the proposed principle.
III. Modeling designs based on Principle 1 and Principle 3
A. Case study by a Particular Brick Press Machine
A particular brick press machine which was supplied by a company in China is taken for case study.
This machine has a four-column cylinder structure with two opposite pressing directions (Fig. 8). The
structure of the two pressing systems is the same, so we only consider the upper pressing system. The
machine has a dual-pump and double-circuit hydraulic system that controls the press head.
Figure 8. A particular brick press machine was supplied by a company in China with a four-column
cylinder structure and two opposite pressing directions.
The hydraulic control system for the press machine is shown in Fig. 9. Note that the machine of Fig. 8 is
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based on Principle 1 (for brevity, in the following, this machine is called old machine). In the old
machine, there are two charging valves in the upper and lower cylinders, respectively.
Figure 9. Hydraulic control system of the old machine based on Principle 1. (1: upper cylinder; 2, 7:
charging valves; 6, 8-11: solenoid directional valve 4: lower cylinder; 5: throttle valves; 12,13: overflow
valves; 14: check valve; 15: pressure gauge; 16: gear pump; 17, 18 : motor; 19: piston pump. Y means
solenoid valves).
At initial time, solenoid directional valves 12 and 13 are in the state of “normally open”, so two pumps
16 and 19 start up with no load. A working circle of the machine is shown in Fig. 10.
Figure 10. One operation cycle of solenoid valves.
In Fig. 10, there are seven actions of the press machine, and each action is controlled by the solenoid
valves. One working circle is described as follows: When the upper cylinder moves downward, charging
valve 2 is open to fill oil into the upper cylinder to drive the upper cylinder move more rapidly. Likewise,
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charging valve 7 is open when the lower cylinder goes upward. When the two cylinders reach the pre-set
position, directional valve 6 places on right, the two cylinders are connected, and the charging valves are
closed. The system can get a higher pressure, and then the pressing process starts. After pressing, the
upper cylinder goes upward by hydraulic force, and the lower cylinder moves back by gravity of itself.
Since the pressure change in the hydraulic system is difficult to test, we will simulate this working
process of hydraulic system by AMESim software. AMESim stands for Advanced Modeling and
Simulation Environment for Systems Engineering, it offers a complete 1D simulation suite to model and
analyze multi-domain, intelligent systems and to predict their multi-disciplinary performance. The
components of the model are described by analytical models representing the hydraulic, pneumatic,
electric or mechanical behavior of the system [5].
B. Modeling for the old machine based on Principle 1
The goal of modeling is to develop a model to calculate the pressure profile in the pressure switching
period. In the modeling, we neglected the noise factors as well as the influence of the dynamic
characteristics of pipeline and fluid elastic modulus. Furthermore, we employed a modeling tool called
AMESim.
Set up the simulation model of the whole system shown in Fig. 11 based on the hydraulic system
working principle 1 [6 - 8].
In this model, the lower cylinder is simplified as one cavity, and the up cavity of the cylinder is
connected to the tank, since the lower cylinder goes back by gravity of itself. Considering the purpose of
this simulation is to find out the source of violent vibrations and popping sounds, the simplification for
the lower cylinder cannot affect the results.
8
Figure 11. AMESim model of the hydraulic control system based on Principle 1. (BAP12: Cylinder;
MAS005: Mass Block; FORC: Press Force; UD00: Signal Source; CV005: Fluid Control One-Way
Valve; TK10: Oil Tank; FP04: Hydraulic Oil Source; HSV34_01: Solenoid Directional Valve; OR003:
One-Way Throttle Valve; RV00: Relif Valve; PV022: Swith Valve; CV000: Check Valve; PM000: Motor;
PU001:Hydraulic Pump).
C. Modeling for the new machine based on Pricnciple 3
The improved hydraulic system based Principle 3 is given in Fig.12, (for brevity, in the following, this
machine is called new machine) the optimized part is marked with a red arrow.
Figure 12. Diagram of the optimized hydraulic system.
Compared with the old machine, one more relieving action was added in the new machine. The
unloading relief valve only acts after keeping pressure and before the cylinder drawing back. Exactly, it
acts on 6th second in this working process. That means the relieving loop unloads the high pressure
gradually before the fluid direction changes.
Based on the hydraulic system diagram, a model was established by AMESim.
The model with relieving loop is shown in Fig. 13.
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Figure 13. The AMESim model with relieving loop
The relieving loop can be simplified as a pilot relief valve and a signal source. The improved part is
labeled with a red arrow in Fig. 13 [9, 10].
IV. Results and Discussion
A. Results of simulation
Main parameters of the model in a working process for the old machine are as follows:
Action cycle: 9 s；
Piston travel: 0.6 m；
Hydraulic pressure：13 MP.
One working circle of the stroke of the upper cylinder is as Table 1:
TABLE 1. One working circle of stroke in upper cylinder
No load Down Apply Hold Back
Time [s] 1 2 2 1 3
Distance [m] 0 0.3 0.1 0 0.5
We set the relieving time as 1 second, and the pressure was reduced from 13 MP to 3 MP. The
simulation curves of the old machine are obtained by AMESim software. For the upper cylinder, here
gives the curves of its displacement, hydraulic pressure and acceleration in Fig. 14 - 16.
10
Figure 14. Displacement versus time of upper cylinder of the old machine.
Figure 15. Pressure versus time in upper cylinder of the old machine.
Figure 16. Acceleration versus time of upper cylinder of the old machine.
Fig. 14 - 16 described the working process of upper cylinder for the old machine. The abscissa
represents time. Fig. 14 shows the displacement of the upper cylinder. As for Fig. 15, there is a sharp
pressure drop on the 6th second, it means that, when the upper cylinder moves back after keeping
pressure for 2 seconds (it is on the 6 seconds in the picture), the pressure drops abruptly. From Fig. 16,
we can see that the acceleration at that time is high. Due to the compressibility of the hydraulic oil and
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the elasticity of the mechanical part, a large amount of energy is stored in the hydraulic cylinder. As a
result, the machine would produce violent vibrations and emit a popping sound when the directional
valves acts. This phenomenon does a serious destruction to the brick press [11, 12].
Subsequently, the simulation curves for the lower cylinder of the old machine are shown in Fig. 17 - 19.
Figure 17. Displacement of lower cylinder.
Figure 18. Pressure in lower cylinder.
Figure 19. Acceleration of lower cylinder.
Also we find that, on the 6th second, the pressure in the lower cylinder drops down sharply and the
acceleration is up to 110 m/s2. That means an analogous incident is emerged in the lower cylinder, so it
12
is not necessary to analyze the problem more.
Meanwhile, the simulation results of the upper cylinder for the new machine were obtained. For the
consideration of impact, we pay attention to the pressure change and acceleration of the upper cylinder.
So Fig. 20 and 21 describe the pressure change in the cylinder and acceleration of the cylinder.
Figure 20. Pressure in upper cylinder after optimization.
Compared with the old machine, it can be concluded that there is a sloping decrease of the pressure in
the upper cylinder from the 6th second to the 7th second, which means that the pressure does not drop
immediately and impact is reducing. In Fig.16, we can see that the acceleration is reduced from 500 m/s 2
to 35 m/s2, it also means that the vibration and impact are decreased greatly.
Figure 21. Acceleration of upper cylinder after optimization.
However, a side effect is brought about, that is, the processing period is extended one second. Since the
whole period is 9 seconds, the new appeared problem can be neglected.
Because the lower cylinder has a similar working condition and process as the upper cylinder, the
simulation of lower cylinder is not repeated here.
B. Experimental validation and practical application
Fig. 22 is the photograph of an experimental prototype. In the beginning of the practical operation, we
found an obvious drawback during the working progress. A lot of noise was generated, especially when
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the cylinder changed directions. It was hard to find the problem since the pressure in the cylinder and
velocity of the press head was difficult to measure. So we developed the simulation method to look for
the problem.
Figure 22. Photograph of an experimental prototype.
From the simulation, we found that, the hydraulic system had a large impact in the pipes when the valve
changed directions mainly because the system is lack of a relief system. After analyzing two principles
of pressure relief, we designed a new pressure relief method by combing the two previous methods, and
then simulated it again. The results showed that the new method is quite useful.
After that, we applied the new method to the prototype. Noise test showed that, the noise level of the
new machine is decreased from 80 decibel to 58 decibel. Impact in the hydraulic system was decreased
significantly, and the working life of the new machine was prolonged greatly. Meanwhile, the products
made of the machine were stronger and smoother than before (Fig. 23).
Figure 23. Products made by the press machine.
V. Conclusions
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This paper discussed the problem of vibration presented in common pressing machinery. One of the
factors related to the vibration is the hydraulic control system. A new hydraulic circuit system was
proposed. By means of a reliable modeling and simulation tool called AMESim, it can be shown that the
design based on the proposed principle worked quite well in comparison with the design based on the
old principle. A particular type of brick press machine was used to illustrate this research and used to
verify effectiveness of the proposed principle. In particular, the noise level of the old machine is about
80 decibel. The new machine based on the proposed principle allows the noise level to be reduced to 58
decibel.
One limitation of the work may be the neglect of the type of materials that are pressed. The current type
of material is coal fly ash, which is quite compliance or less stiffness. For other types of materials, due
to different compliances, the vibration suppressing behavior of the proposed control system needs to be
examined, which is an ongoing future work.
Acknowledgment
The authors would like to express their sincerely appreciation to Mr. Gang Li, student from Nanjing
University of Science & Technology, and Mr. Xianchun Tian, Mr. Huaitong Jiang, Mr. Feng Yu,
engineers from Jiangsu Tengyu Machinery Manufacture Co., Ltd., for their technical and experimental
cooperate. Financial support from Jiangsu Tengyu Machinery Manufacture Co., Ltd. is also appreciated.
References
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hydraulic inertia damper”, Journal of Materials Processing Technology, vol. 112, pp. 205-213, 2001.
[3] J. W. Yin, Q. J. Wang, T. H. Liu, “Development on two-way hydraulic press”, Journal of
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[4] S. Y. He, X. Ma, S. J. Zhong, “Research on the depressurized circuit of hydraulic press”, Journal of
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Open Journal of Mechanical Engineering, Vol.1 No.

Optimal Design of Hydraulic System for an Industrial Press

A. The generic operation of press machine

Figure 2. Generic operation of press head.

Figure 3. Generic structure of press.

Figure 4. Pressure relief method with a throttle valve.

Figure 5. Pressure relief method with a pressure valve group.

Figure 7. Conceptual design of the proposed principle.

III. Modeling designs based on Principle 1 and Principle 3

A. Case study by a Particular Brick Press Machine

Figure 10. One operation cycle of solenoid valves.

B. Modeling for the old machine based on Principle 1

C. Modeling for the new machine based on Pricnciple 3

Figure 12. Diagram of the optimized hydraulic system.

Figure 13. The AMESim model with relieving loop

IV. Results and Discussion

Figure 17. Displacement of lower cylinder.

Figure 18. Pressure in lower cylinder.

Figure 19. Acceleration of lower cylinder.

Figure 20. Pressure in upper cylinder after optimization.

Figure 21. Acceleration of upper cylinder after optimization.

B. Experimental validation and practical application

Figure 22. Photograph of an experimental prototype.

Figure 23. Products made by the press machine.

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