China's largest tonnage electric screw press was successfully developed in Wuhan

Recently, China's largest tonnage of 4,000 tons of servo direct drive electric screw press was successfully developed in Wuhan for the production of key components of advanced aero engines.

Dr. Feng Yi, general manager of Wuhan Xinweiqi Technology Co., Ltd., introduced that the nominal pressure of the press is 4,000 tons, the long-term allowable load is 6,400 tons, the cold shock force is 8,000 tons, and the full energy of the moving part is 1,000 kilojoules. The deformation rate and the position of the slider are accurately controlled, and the design and performance indicators have reached or partially exceeded similar foreign products, once again refreshing the new record of this type of domestic equipment, and can better realize the high-precision, efficient and stable production of forging products.

Dr. Yu Jun, Chief Engineer of Sunwiki, said that the new electric screw press applies three core technologies: the design of high-power servo motor and the precise control technology of high response of large load, the failure prediction method and system of electric screw press based on data-driven, and the life prediction method and system of key components of electric screw press based on data fusion.

The core technology effectively improves product performance, and the new electric screw press has five advantages: high precision, high efficiency, safety and reliability, energy saving and environmental protection, and flexible control of speed curve. The high precision is reflected in the precise control of the striking energy, the energy repeat control accuracy is less than or equal to plus or minus 2.5%, the long slider and long guide mechanism are designed, the guidance is accurate and the response is faster, and the high-strength cast steel split combination prestressed fuselage ensures the forming stability. The high efficiency is reflected in the use of high-power permanent magnet synchronous motor, rotor permanent magnet self-excitation, motor efficiency greater than or equal to 95%, reduce the mold load, increase the mold life by more than or equal to 5%, have better acceleration performance, and increase production efficiency by more than or equal to 5%. Safety and reliability are reflected in the combined flywheel design, overload safety protection, new brake design, braking fast response, and the main components are made of materials higher than the industry standard. Energy saving and environmental protection are embodied in: motor direct drive, energy saving 60-70% compared with friction transmission products, energy saving about 10% compared with gear transmission products, no transmission noise, improve working environment, simple structure, strong durability, maintenance-free. The flexible control of the speed curve is suitable for the characteristics of slow forming speed and fast idle stroke speed in the forging process of non-ferrous metals such as aluminum alloy and titanium alloy.

Ding Xiaoyu of Wuxi Parker New Material Technology Co., Ltd. said that we finally chose to purchase a total of 4 sets of 400 tons, 1000 tons, 2000 tons and 4000 tons of servo direct drive equipment from Xinweiqi after the necessary selection, which is to value the technological advancement of servo direct drive, the cost performance of products, the ability of after-sales service guarantee and the timeliness of delivery. At present, the 4 pieces of equipment have passed the factory acceptance and have been sent to the customer's site for use.

Xia Juchen, a senior professor at Huazhong University of Science and Technology, said that after nearly a year of investigation, MAHLE Sanhuan Valve Drive (Hubei) Co., Ltd. found that the J58K electric screw press developed by New Weiqi Company is comparable to the performance of the German Lascaux electric screw press, and the price is about 1/5 of that of Lascaux, Germany. With an annual output of more than 42 million high-end valves, it has become the first large valve enterprise in Asia, compared with traditional equipment and technology: the material utilization rate has increased by more than 12%, the qualification rate of forgings has increased from about 95% to nearly 100%, and the mold life has increased to 180,000 pieces, with significant economic benefits.

Industrial machine is "the machine of manufacturing machine", forging equipment is the most important industrial machine, and heavy forging equipment is a symbol of the strength of a country's high-end equipment manufacturing industry, mass manufacturing of aerospace equipment group, complete production lines of rail transit, module units and parts of the automobile industry, etc., all need heavy forging equipment for industrial support.

In the early 90s of last century, a large number of foreign machine tools poured into the Chinese market, but in the core technology, foreign companies have adopted a strategy of suppression and blockade. Professor Huang Shuhuai, then president of Huazhong University of Science and Technology, founded New Wits, advocating independent innovation to solve the problem of "stuck neck". In 2003, the first domestic electric screw press was developed, filling the gap in China. Subsequently, New Wiaki entered the industrialization in an all-round way. In 2016, it took the lead in developing the J58ZK series servo direct-drive electric screw press in China, a high-end forging press with the advantages of zero transmission, high efficiency and high precision, and no motion noise. In September 2023, the heavy-duty plant with a single piece of 300-ton lifting capacity broke ground, and the next step will be to develop the world's first set of 10,000-ton servo direct-drive CNC electric screw presses representing the highest international level.

Focusing on the urgent demand for automation, informatization and intelligence in the forging production line, Xinweiqi has upgraded its business focus from a single forging equipment manufacturer to an overall solution provider. With die forging and forming equipment as the core, combined with a number of cutting-edge technologies and equipment such as mold technology, machine vision, digital twin, etc., and using the self-developed intelligent forging cloud platform, the production process data such as product size and margin, as well as the automatic collection of production site data such as production line output, electricity, and production beat, will store the data in real time, and conduct in-depth analysis at the same time to accurately control the consistency of the product production process and the stability of the production line status.

Since its establishment, New Weiqi has always adhered to the guidance of technological innovation, successively delivered more than 1,800 sets of forging equipment, built more than 140 automated forging lines, and served more than 500 users. It has won a total of 2 national awards, 9 provincial and ministerial awards, and was selected as one of the top ten scientific and technological advances in China's intelligent manufacturing, and won the title of national specialized, special and new key little giant enterprise in 2021.