To ensure pressure control accuracy in high-temperature environments, the Servo Intelligent Press requires a comprehensive solution encompassing hardware design, material selection, heat dissipation optimization, control algorithms, and environmental adaptability. Its core lies in using technological means to mitigate the negative impacts of high temperatures on the mechanical structure, electrical performance, and lubrication system, thereby maintaining the equipment's stability under extreme operating conditions.
The impact of high temperatures on the Servo Intelligent Press is primarily manifested in mechanical structural deformation. Thermal expansion of metal components leads to changes in transmission clearances; for example, the pitch error of the ball screw increases, directly affecting displacement accuracy. Therefore, the equipment must use alloy materials with low coefficients of thermal expansion to manufacture key transmission components, and employ pre-stressed assembly processes to offset some deformation. Simultaneously, laser calibration technology can monitor the straightness of the guide rails in real time, and combined with a closed-loop control system, dynamically corrects errors to ensure that the pressure head's position accuracy is unaffected by temperature fluctuations.
The stability of the electrical system is another key aspect of high-temperature control. The permanent magnets inside the servo motor are prone to demagnetization at high temperatures, leading to torque output attenuation; electronic components may experience accelerated aging due to thermal stress, causing signal distortion. To address this issue, the equipment requires the use of neodymium iron boron magnets with higher temperature resistance, and temperature sensors embedded in the motor windings. A PID algorithm is used to adjust current parameters in real time to maintain a stable magnetic field strength. Furthermore, the circuit boards of the driver and controller must use high-temperature resistant substrates, and key chips must be equipped with heat sinks to prevent performance degradation due to overheating.
Lubrication system performance degradation is a typical challenge in high-temperature environments. Traditional greases lose viscosity at high temperatures, making it difficult to form an effective oil film, leading to increased friction coefficients and decreased transmission efficiency. Servo intelligent presses require synthetic lubricants with an operating temperature range covering -40℃ to 150℃, and excellent shear resistance. Some high-end models also introduce active lubrication systems, using oil pumps to precisely deliver lubricating oil to the friction pairs, and using oil temperature sensors to dynamically adjust the flow rate, ensuring optimal lubrication at all times.
Adaptive optimization of the control algorithm is crucial for ensuring accuracy in high-temperature environments. Traditional PID control, with its fixed parameters, struggles to handle nonlinear disturbances caused by temperature changes. Modern servo presses commonly employ adaptive control algorithms. By collecting multi-dimensional data such as pressure, displacement, and temperature in real time, they construct dynamic models and automatically adjust control parameters. For example, when a decrease in system stiffness due to increased oil temperature is detected, the algorithm preemptively increases the pressure compensation value to offset overshoot caused by changes in the oil's elastic modulus. Some models also incorporate feedforward control technology, pre-calculating the motor's output torque based on preset process curves to further shorten response time.
Environmental adaptability design must be implemented throughout the entire equipment lifecycle. In terms of structural layout, heat-generating components such as servo motors and drivers should be kept away from precision components such as pressure sensors to avoid measurement errors caused by localized overheating. Heat dissipation design must balance efficiency and reliability; forced air cooling systems must be equipped with dust filters to prevent dust intrusion in high-temperature environments; liquid cooling systems must use corrosion-resistant coolants and have flow switches to monitor circulation. Furthermore, the equipment casing must be made of heat-insulating materials to reduce the impact of external heat radiation on internal components.
From a long-term operational perspective, maintenance strategies for high-temperature environments are equally crucial. The equipment needs to be equipped with an intelligent diagnostic system to identify potential faults in advance through vibration analysis, oil level detection, and other technologies, such as bearing wear or seal aging. Maintenance cycles should be dynamically adjusted according to actual operating conditions; for example, shortening lubricant change intervals in continuously high-temperature environments. Operator training should emphasize operational procedures under high-temperature conditions, such as avoiding prolonged full-load operation of the equipment or utilizing production breaks to activate cooling circulation.
