ENHANCING THE ENERGY EFFICIENCY OF AN ELECTROHYDRAULIC DRIVE IN A DIE-CUTTING PRESS USING A FLYWHEEL AND A FREQUENCY CONVERTER

Abstract

This paper investigates methods to enhance the energy efficiency and dynamic performance of electrohydraulic drives in die-cutting presses, which are widely utilized in mechanical engineering and processing industries for stamping and cutting operations. Conventional drive systems often exhibit uneven motor loading, substantial peak power demands, and significant energy losses during cyclic operation. To address these challenges, the study explores the integration of a flywheel as a mechanical energy storage element, which mitigates load fluctuations, reduces dynamic stresses, and provides partial energy recovery during high-demand phases. The functional role of the flywheel is analyzed for press types PVG-8-1-0 and PVG-8-2-0, including calculations of its moment of inertia, energy capacity, and structural parameters, taking into account permissible speed variations, operational constraints, and mechanical strength considerations. In parallel, the application of a frequency converter for motor control is investigated, enabling smooth acceleration, deceleration, and real-time speed adjustment to match varying load conditions, thereby reducing peak currents, minimizing energy losses in the hydraulic system, and improving overall system reliability. The interaction between the flywheel and frequency-controlled electric drive is shown to produce a synergistic effect, optimizing energy utilization while maintaining technological performance. A systematic methodology is proposed for the design and modernization of die-cutting press drives, encompassing load analysis, flywheel parameter selection, mechanical verification, and coordinated integration of motor, pump, and control system. The novelty of the approach lies in treating the drive as a fully integrated system, where mechanical energy storage, electric drive control, and hydraulic operation are harmonized for maximum energy efficiency. The practical implications are significant, offering opportunities to modernize existing equipment, enhance operational stability, reduce energy consumption, and extend the service life of critical drive components, while supporting sustainable industrial practices.