Energy consumption characteristics analysis and energy-saving optimization of hydraulic forging press based on electromechanical-hydraulic coupling

Die forging hydraulic presses, essential for metal forming in large-scale component manufacturing, often suffer from low energy utilization. Due to system complexity and load uncertainty, accurately characterizing the dynamic energy consumption during operation remains a significant challenge. Additionally, determining the optimal system configuration to minimize energy consumption in the forging process is difficult. To address these issues, this study proposes an electromechanical-hydraulic coupling model to dynamically quantify energy dissipation in key components of the hydraulic press during operation. The influence of motor speed, pump displacement, and overflow pressure settings on system energy consumption is analyzed, and an energy efficiency optimization strategy based on system parameter matching is developed. The accuracy of the proposed energy consumption model is validated through forging experiments on scaled-down aircraft connection components, with the steady-state error of each characteristic curve remaining within 5.5%. Furthermore, the optimized operating parameters result in a 18,753.3 J and 26,710.3 J reduction in motor and pump energy consumption, respectively, while overflow and throttling losses are reduced by 138,986.8 J and 30,357.1 J, leading to an overall system energy consumption reduction of 61.9% in a single operating cycle. Considering typical factory operation, this corresponds to an estimated annual energy saving of approximately 1400 kWh, demonstrating the practical significance of the proposed optimization strategy.