Efficient application of axial piston variable displacement pump A4VSO in forging solutions

This article comprehensively discusses the key applications and technical advantages of the axial piston variable pump A4VSO in the forging industry. As a benchmark product in the field of hydraulic axial piston pumps, the A4VSO series has become the core power element of the hydraulic system of modern forging equipment with its excellent high-pressure performance, flexible variable control and long-life design. The article analyzes in detail the working principle, technical characteristics, selection points and specific application cases of the A4VSO pump in the forging process, and provides professional advice on installation and maintenance and forecasts on future technology development trends, providing a comprehensive technical reference for forging equipment manufacturers and end users.

1. Special requirements of forging industry for hydraulic power

As an important means of metal forming, forging technology has an irreplaceable position in the fields of automobile manufacturing, aerospace, military equipment, etc. With the development of Industry 4.0 and intelligent manufacturing, modern forging equipment has put forward higher requirements for hydraulic systems: high pressure and large flow , precise control , energy efficiency optimization , and reliable stability . These stringent technical requirements make it difficult for traditional quantitative pump systems to meet them, and variable displacement piston pump technology has become the best solution with its unique advantages.

has become the preferred power source for hydraulic systems in the forging industry with its advanced design of swash plate axial piston variable displacement pump . This series of pumps can not only completely replace imported products of the same specifications, but also have outstanding performance in interchangeability, reliability and performance parameters. Its rated working pressure is up to 350Bar (35MPa), and the peak pressure can reach 400Bar (40MPa ) , which is particularly suitable for high-pressure and high-flow application scenarios such as forging presses and stamping machines.

This article will systematically introduce the technical characteristics of the A4VSO axial piston variable displacement pump, deeply analyze its specific application solutions in forging equipment, and provide professional selection and maintenance suggestions to help readers fully understand this efficient hydraulic power solution.

2. Technical characteristics of A4VSO axial piston variable pump

2.1 Basic structure and working principle

A4VSO series is a swash plate type axial piston variable displacement pump , designed for open circuit high-efficiency hydraulic drive. Its core working principle is based on the swash plate driving multiple plungers and cylinders arranged axially to rotate together, and the reciprocating motion of the plungers relative to the cylinder body realizes the suction and discharge of oil.

As the swashplate rotates with the plunger assembly:

1. Oil suction process : The space formed by the plunger and the cylinder increases, forming a negative pressure to suck in the oil

2. Oil discharge process : The space formed by the plunger and the cylinder body is reduced, and the oil is squeezed into high-pressure oil for output

3. Variable control : The pump displacement can be adjusted steplessly by changing the inclination of the swash plate to achieve precise flow control

This unique working principle gives the A4VSO pump significant advantages such as compact structure , small radial size , small inertia and high volumetric efficiency , and is particularly suitable for the application requirements of high-pressure systems.

2.2 Key technical parameters and performance advantages

A4VSO series hydraulic axial piston pumps provide a variety of displacement specifications from 40 to 1000 ml/rev, among which medium-sized displacements such as 180, 250, and 355 are particularly suitable for forging equipment applications. Its main performance features include:

· High-pressure performance : rated working pressure 350Bar, peak pressure up to 420Bar, meeting the extreme working conditions of forging presses

· Efficient variable control : Provides DR/DRG constant voltage control, LR hyperbolic constant power control, EO2 electrical proportional control and other variable forms

· Long life design : high-precision aviation-grade full roller bearings and specially optimized sliding shoe-swash plate friction pair significantly extend the service life

· Low noise operation : Optimized valve plate design and precision manufacturing process ensure that the operating noise is lower than the industry standard

· High power density : excellent power/weight ratio, reducing equipment space occupation

· Medium adaptability : Mineral oil or HFC water glycol fire-resistant hydraulic oil can be used to meet the needs of different working conditions

Table: A4VSO series main displacement specifications and performance parameters

2.3 Advanced variable control technology

A4VSO series hydraulic axial piston pumps provide a variety of variable control modes, which can be flexibly selected according to different forging process requirements:

1. DR/DRG constant pressure control : When the system pressure reaches the set value, the pump automatically reduces the displacement to maintain constant pressure, which is particularly suitable for forging processes that require stable pressure.

2. LR hyperbolic constant power control : Automatically adjust the displacement according to the load, so that the pump always works at the optimal power curve, improving energy efficiency

3. EO2 electrical proportional control : precise control of displacement through electrical signals, seamless integration with PLC system, suitable for intelligent forging lines with high degree of automation

4. HD hydraulic pressure control : automatically adjusts according to system pressure changes to maintain the best match between pressure and flow

These advanced variable control technologies enable the A4VSO pump to accurately match the power requirements of each stage of the forging process, avoiding energy waste and significantly reducing system operating costs.

2.4 Design for adaptability to special environments

Aiming at the harsh environment of forging workshops, such as high temperature and high dust, the A4VSO pump is specially designed with a variety of adaptability features:

· Flame-resistant media version : F2 type is optimized for HFC water glycol media, no external bearing flushing is required, simplifying system design

· Strengthened seal : Strengthened PTFE shaft seal and special bearing design to extend the medium adaptability and service life

· High temperature adaptability : Optimized valve plate and friction pair design ensures stable operation in high temperature environment

· Pollution tolerance : Although the oil cleanliness level is required to be NAS9, the tolerance to accidental contamination is improved through special design.

These features enable the A4VSO hydraulic axial piston pump to work reliably in various forging production environments and reduce unplanned downtime.

3. Typical application of A4VSO in forging equipment

There are many types of forging equipment with different process requirements. The A4VSO axial piston variable pump has become an ideal power source for various forging machinery hydraulic systems due to its flexible and variable characteristics and high pressure and large flow performance. The following analyzes several typical application scenarios.

3.1 Forging press hydraulic system

Forging presses require extremely high instantaneous pressure and precise motion control. A4VSO pumps are usually configured in the following ways in such equipment:

· Main pump selection : A4VSO250 or A4VSO355 specifications, DR constant pressure control, providing a stable high-pressure oil source

· System design : Multiple pumps are connected in parallel to meet the instantaneous high flow demand through the assistance of accumulators

· Pressure control : The working pressure is usually set in the range of 280-320Bar, adjusted according to the specific forging process

· Energy-saving design : using LR constant power control Control or load-sensitive control automatically reduces displacement when the idle stroke drops rapidly

A large forging company uses an 8,000-ton forging press driven by an A4VSO355DR pump group, which saves 35% energy compared to the original fixed-displacement pump system and improves forging accuracy and repeatability.

3.2 Hydraulic power unit for stamping production line

The automotive panel stamping production line has special requirements for the hydraulic system: fast idle stroke, low-speed precision stamping, and high repeatability. The advantages of A4VSO in such applications include:

· Quick response : The swash plate has a short adjustment time to meet the requirements of high-speed stamping cycles

· Precise flow control : EO2 electrical proportional control achieves perfect coordination with servo valve

· System integration : The through-shaft structure is easy to combine with the gear pump to provide differentiated pressure and flow for different functions

· Stable pressure : good pressure cut-off characteristics to avoid pressure fluctuations at the moment of stamping

Modern press lines often use the A4VSO180EO2 pump in combination with a servo control system to achieve millimeter-level position control accuracy while saving more than 25% energy compared to traditional systems.

3.3 Multi-station forging press hydraulic system

Multi-station forging presses need to provide power to multiple actuators at the same time, and the loads of each station vary greatly. Typical application features of A4VSO pumps in such equipment:

· Multi-pump combination : 3-4 A4VSO125 or A4VSO180 pump groups are used to serve different workstations

· Independent control : Each pump can be set with different pressure cut-off values to accurately match the needs of each station

· Flow distribution : Automatically balance the load of each pump through LR constant power control to optimize the total power consumption

· Redundant design : One backup and one backup configuration ensures continuous production, and system performance remains consistent during switching

After a bearing ring multi-station forging machine adopted four A4VSO125LR pump units, the equipment utilization rate increased from 85% to 93% and the failure rate decreased by 40%.

3.4 Application of special forging equipment

In addition to conventional forging equipment, A4VSO hydraulic axial piston pumps are also widely used in various special forging equipment:

· Isothermal forging hydraulic system : Stable pressure needs to be maintained for a long time. A4VSO's DR control ensures that the pressure fluctuation is less than ±2Bar.

· Powder forging press : The smoothness of the action is extremely high, and the low noise and smooth flow characteristics of A4VSO are a perfect match

· Multi-directional die forging equipment : multiple hydraulic cylinders work together, and the quick response of A4VSO ensures the synchronization accuracy of the movements

· High-speed forging hammer : The instantaneous flow demand is large, and A4VSO is equipped with a large-capacity accumulator to provide peak flow

These special applications fully demonstrate the technical adaptability and performance reliability of the A4VSO pump, consolidating its core position in the forging industry.

Table: Typical configuration of A4VSO in different forging equipment

4. A4VSO pump selection and system design points

Correct selection and system design are the key to ensure the best performance of the A4VSO axial piston variable displacement pump in forging equipment. This section provides professional selection guidance and technical suggestions.

4.1 Displacement Specification Selection Principles

The following factors should be considered when selecting the displacement specification of the A4VSO pump:

Flow requirements : Calculate the maximum flow requirements based on the hydraulic cylinder size and operating speed, and select a pump that can meet the requirements at 1500-1800rpm.

o Calculation formula: Q = (A × v) / 600 (L/min)

o Where A is the effective area of the hydraulic cylinder (cm²), v is the working speed (mm/s)

Pressure requirements : confirm the maximum working pressure and peak pressure of the equipment to ensure that it does not exceed the rated 350Bar and peak 400Bar limits of the pump .

Power matching : Check whether the drive motor power is sufficient to avoid overload

o Power calculation formula: P = (p × Q) / (600 × η) (kW)

o Where p is pressure (Bar), Q is flow rate (L/min), and η is overall efficiency (usually 0.85-0.9)

Working system considerations : For continuous high-load work, choose a larger size, and for intermittent work, choose according to actual needs.

For most forging equipment, A4VSO125 to A4VSO355 are common specifications, among which A4VSO250 is considered to be the "universal specification" that balances flow, pressure and cost factors.

4.2 Guidelines for selecting variable control methods

A4VSO provides a variety of variable control methods, each with its own characteristics, the selection should be combined with the forging process requirements:

1. DR/DRG constant pressure control :

o Applicable scenarios: Forging and pressure-maintaining processes that require stable pressure

o Advantages: stable pressure, good energy saving effect

o Note: When multiple pumps are connected in parallel, the pressure cut-off value must be set accurately

2. LR hyperbolic constant power control :

o Applicable scenarios: occasions where the load changes greatly but the total power needs to be limited

o Advantages: Automatically adapt to load and protect power source

o Note: Not suitable for scenarios requiring precise pressure control

3. EO2 electrical proportional control :

o Applicable scenarios: Systems with high automation and need to be integrated with PLC

o Advantages: Precise control, can realize complex control strategies

o Note: Need to match the electronic control system, the cost is relatively high

4. Combined control :

o Common combination: DRG+LR realizes constant voltage and constant power dual protection

o Applicable scenarios: key equipment with high requirements for system security

For most forging applications, DR control can meet basic needs; high-end equipment is recommended to use EO2 control to achieve more intelligent energy management.

4.3 Key points in hydraulic system design

When designing a hydraulic system for forging equipment around an A4VSO pump, special attention should be paid to the following aspects:

Oil circuit design:

· When through-drive is used, multiple pumps can be connected in series to provide independent oil sources for different functions

· The diameter of the oil inlet pipeline is sufficient to ensure that the oil inlet pressure is not less than 0.2Bar

· The oil drain line is led back to the oil tank separately to avoid back pressure affecting the pump housing seal

Auxiliary component selection:

· Select an oil inlet filter with a filtration accuracy of βₓ≥75 to ensure the oil cleanliness level is NAS9

· It is recommended to use high-pressure filters with βₓ≥200 and a rated pressure 20% higher than the maximum system pressure.

· The accumulator capacity is calculated based on the instantaneous flow demand, usually 20-30% of the main pump flow.

Security protection:

· The system is equipped with a safety valve, and the pressure setting is 5-10% higher than the pump cut-off pressure.

· Temperature monitoring alarm, warning when oil temperature exceeds 65℃, shutdown protection at 80℃

· Online monitoring of oil level and contamination, preventive maintenance

Energy-saving design:

· The multi-pump system uses a combination of pumps of different specifications to match the flow requirements of different working conditions

· Consider combining variable frequency drive with variable displacement pump to further reduce energy consumption

· To recover the downward potential energy of the forging press, secondary adjustment technology can be used

4.4 Special considerations for fire-resistant hydraulic fluid systems

Forging equipment in high temperature or flammable environments often requires the use of fire-resistant hydraulic oils such as HFC water glycol. At this time, the following points should be noted when selecting the A4VSO pump:

· Choose specially designed F or F2 pumps to adapt to HFC media characteristics

· The F2 model does not require external bearing flushing, simplifying system design

· The working pressure needs to be reduced by about 10% and the speed by 15-20%.

· The fuel tank is designed with 30% larger volume to enhance heat dissipation

· Seals and hoses must be compatible with water glycol media

A correctly selected A4VSO pump can achieve performance and life similar to mineral oil in HFC medium, providing safe and reliable hydraulic power for high-temperature forging workshops.

5. Installation, commissioning and maintenance

Correct installation, standardized commissioning and scientific maintenance are the key to ensure the long-term stable operation of the A4VSO axial piston variable pump in forging equipment. This section provides professional technical guidance.

5.1 Installation specifications and precautions

Mechanical installation:

· Adopt elastic coupling to ensure axial deviation <0.1mm and radial deviation <0.2mm

· The pump shaft is not subject to radial force and the mounting bracket has sufficient rigidity

· For through-drive pumps, the additional load on the subsequent pumps does not exceed the permissible value.

Hydraulic connections:

· The oil inlet pipe diameter is sufficient and the flow rate does not exceed 1.2m/s

· The oil drain port is led back to the oil tank separately, and the rising slope of the pipeline is >5° to avoid air blockage

· The oil leakage back pressure should not exceed 0.15MPa, otherwise it will affect the sensitivity of the servo variable mechanism.

Electrical connection (variable pump):

· The proportional solenoid valve cable is well shielded and kept away from the power line.

· The control signal matches the power supply voltage and the polarity is correct

· Reliable grounding to avoid electromagnetic interference

Check before initial startup:

· Confirm that the direction of rotation is correct (usually clockwise when viewed from the shaft end)

· The oil level in the tank is sufficient and the oil type is correct

· The oil inlet pipeline is filled with oil and the air is exhausted.

5.2 Debugging steps and parameter settings

No-load debugging:

1. Loosen the pressure adjustment screw to put the pump at minimum pressure.

2. Start the motor, check the steering and any abnormal noise

3. Run continuously for 10 minutes and check that the shell temperature should rise evenly

Pressure setting:

1. DR control pump: gradually tighten the pressure adjustment screw to the required setting value

§ Forging presses are usually set at 280-320 Bar

2. LR control pump: set the maximum pressure first, then adjust the power curve

3. EO2 control pump: maximum pressure and flow characteristics set via controller

Traffic debugging:

1. Check whether the speed of each action meets the design requirements

2. Multi-pump system needs to balance the flow contribution of each pump

3. Verify variable mechanism response time and stability

Safety Testing:

1. Test the pressure cut-off function to confirm that the pump can change the pressure in time when the set pressure is reached

2. Check whether the safety valve opening pressure is normal (5-10% higher than the pump cut-off pressure)

3. Simulate fault conditions to verify the effectiveness of protection devices

5.3 Daily maintenance and regular maintenance

Daily inspection items:

· Oil level, oil temperature and oil quality

· Pump operating noise and vibration levels

· External leak check

· Filter differential pressure indication

Regular maintenance content:

· Every 500 hours: Check the coupling alignment and tighten the mounting bolts

· Every 1000 hours: Replace the oil inlet filter and take samples to test the oil contamination

· Every 2000 hours: Check the flexibility of the variable mechanism and test the control performance

· Every 4000 hours: Replace the high pressure filter and fully check the pump technical status

Oil management points:

· Maintain oil cleanliness at NAS9 level and regularly check contamination

· Control the oil temperature in the optimal range of 30-65℃

· Monitor moisture content (<0.1%) and acid value changes

· Do not mix oils of different brands and clean the system thoroughly when changing oil

5.4 Common fault diagnosis and troubleshooting

Insufficient or fluctuating pressure:

· Possible causes: variable mechanism stuck, control valve failure, internal wear of the pump

· Treatment: Check the control oil circuit, test the variable mechanism, and measure the pump volumetric efficiency.

Abnormal noise:

· Possible causes: cavitation, bearing damage, loose internal parts

· Treatment: Check the oil inlet conditions, measure the housing vibration, and disassemble and inspect if necessary.

Traffic drop:

· Possible causes: swash plate limit change, control signal deviation, pump wear

· Treatment: Check control signal, test maximum displacement, measure system leakage

overheat:

· Possible causes: Excessive internal leakage, improper oil viscosity, insufficient cooling

· Action: Check volumetric efficiency, verify oil specifications, evaluate heat dissipation conditions

Variables are slow to respond:

· Possible causes: Insufficient control pressure, variable piston stuck, control valve failure

· Treatment: Check the control oil circuit, clean the variable mechanism, and test the valve response

Establishing a comprehensive fault recording and analysis system will help detect potential problems in advance and avoid major failures.

5.5 Long-term out-of-service maintenance measures

When the forging equipment needs to be shut down for a long time, special maintenance measures should be taken for the A4VSO pump:

1. Drain the old oil in the pump and inject new oil containing rust inhibitor

2. Manually crank the bearing for several cycles to form an oil film on the surface of the bearing and friction pair.

3. The exposed machined surface is coated with anti-rust oil and the oil port is sealed with a screw plug

4. The variable mechanism is placed in the middle position to release the spring stress

5. Store in a dry environment and check the rust-proof status regularly

When reactivating, you should first manually crank the engine to check, and then put it into operation step by step according to the initial startup procedure.

6. Technical and economic analysis and case studies

6.1 Comparative analysis with traditional metering pump system

The use of A4VSO axial piston variable displacement pump in forging equipment has significant advantages over traditional fixed displacement pump systems:

Energy consumption comparison:

· The metering pump system adjusts the pressure through the overflow valve, and a large amount of energy is wasted in the form of heat energy

· Variable displacement pump adjusts output according to load demand, typically saving 30-50% energy

· After the transformation, a 2,000-ton forging press machine achieved a 42% energy saving, saving about 180,000 kWh of electricity per year.

Performance comparison:

· Variable pump pressure control is more precise and forging size consistency is improved

· Stepless flow adjustment to meet the needs of different process stages

· Reduce hydraulic shock and improve system reliability

Cost comparison:

· Initial investment: 20-30% higher for variable pump systems

· Operating cost: 40-60% lower than variable pump system

· Payback period: usually 1-2 years

Maintenance comparison:

· Variable pump oil temperature is lower and oil life is extended

· Reduce overflow conditions and reduce component wear

· The system is simpler and has fewer failure points

Table: Comprehensive comparison between A4VSO variable pump system and fixed pump system

6.2 Analysis of Typical Application Cases

Case 1: Energy-saving transformation of large forging press

The 1600-ton forging press of a heavy machinery plant originally used a quantitative pump + proportional valve system, which had problems of high energy consumption and high oil temperature.

· The main pumps were replaced with two A4VSO355LR pumps with constant power control

· Increase the auxiliary oil supply of the accumulator to meet the instantaneous flow of fast forging

Actual measurement after transformation:

o Energy consumption reduced by 38%

o Oil temperature dropped from 72°C to 58°C

o Improved forging accuracy, reduced scrap rate by 25%

o Payback period: 14 months

Case 2: Hydraulic system upgrade of multi-station cold forging machine

The original system pressure of a 12-station cold forging machine in an automobile parts factory fluctuated greatly, affecting product quality. Solution:

· Four A4VSO125DR pumps are used to control different workstations.

· Accurately set the pressure cut-off value of each pump to form a pressure gradient

· Effect after upgrading:

Pressure fluctuation reduced from ±15Bar to ±3Bar

Product dimensional tolerance increased by 30%

System noise reduction 8dB

Case 3: High temperature workshop forging production line

The ambient temperature of a special steel forging workshop is high and the original system fails frequently. Renovation plan:

· A4VSO250F2 pump is selected to adapt to HFC water glycol medium

· Optimize pipeline layout to reduce pressure loss

· Performance after transformation:

Improved system reliability, MTBF extended by 3 times

Eliminate Hydraulic Oil Fire Hazards

Maintenance costs reduced by 40%

6.3 Life Cycle Cost Analysis

To evaluate the economic feasibility of using the A4VSO pump in a forging machine, the life cycle cost (LCC) must be considered:

Initial Cost (CapEx):

· Pump unit purchase cost

· System transformation cost

· Installation and commissioning costs

Operating costs (OpEx):

· Energy consumption (60-70%)

· Maintenance costs

· Fluid and filter replacement

· Downtime loss

Residual value:

· Residual value of equipment when it is retired

· Trade-in discount

Typical life cycle cost distribution of A4VSO pump in forging equipment:

· Initial cost: 15-25%

· Energy costs: 60-70%

· Maintenance cost: 10-15%

· Residual value: 2-5%

By optimizing selection and system design, energy and maintenance costs can be significantly reduced, and even if the initial investment is higher, the overall LCC is usually lower.

6.4 ROI Calculation Example

A company is considering upgrading its traditional fixed-displacement pump forging machine to an A4VSO variable-displacement pump system:

Basic data:

· Renovation investment: 280,000 yuan

· Annual operating time: 6000 hours

· Original system power: 110kW

· Estimated energy saving: 35%

· Electricity price: 0.8 yuan/kWh

Energy saving benefit calculation:

· Annual electricity saving: 110kW×35%×6000h=231,000 kWh

· Annual electricity savings: 231,000 × 0.8 = 184,800 yuan

Other benefits:

· Maintenance cost reduction: about 20,000 yuan/year

· Waste reduction: about 30,000 yuan/year

· Total annual income: about 235,000 yuan

Payback period:

· Simple payback period: 28/23.5≈1.2 years

· Considering the time value of money: about 1.5 years

This case shows that energy-saving transformation of A4VSO system is usually very economical.

7. Future development trends and technology prospects

7.1 Intelligence and IoT Integration

In the future, the application of A4VSO axial piston variable pump in the forging field will deeply integrate intelligent technology:

· Condition monitoring : integrated pressure, temperature, and vibration sensors to monitor the health status of the pump in real time

· Predictive maintenance : Predict remaining service life based on big data analysis and optimize maintenance plans

· Adaptive control : automatically optimizes the operating point according to process parameters and load changes

· Remote diagnosis : remote fault analysis and guidance through the Industrial Internet

Rexroth has begun embedding smart sensors in its new generation of pumps to provide basic data support for smart forging plants.

7.2 Further Improvement of Energy Efficiency

In the face of increasingly stringent energy efficiency requirements, A4VSO pump technology will continue to optimize:

· New friction pair material : Reduce internal leakage and increase volumetric efficiency to over 98%

· Optimized control algorithm : more accurate load matching, reducing wasted work

· Hybrid power system : combined with variable frequency drive to achieve secondary regulation

· Energy recovery technology : using the downward potential energy of the forging machine to generate electricity

These innovations will increase the energy efficiency of forging equipment hydraulic systems by another 15-20%, further reducing production costs.

7.3 Application of New Materials and New Processes

Advances in materials technology will push the performance boundaries of the A4VSO pump forward:

· High-strength and lightweight materials : Increase power density and reduce volume and weight

· Surface treatment technology : such as DLC coating, extending the life of key friction pairs

· Composite material application : replace some metal parts, reduce noise and cost

· Additive manufacturing : integrated molding of complex flow channels to optimize hydraulic performance

These innovations are expected to enable the next generation A4VSO pump to operate at pressures exceeding 400 Bar while extending its life by 30%.

7.4 Green and Environmentally Friendly Direction

Stricter environmental regulations will drive the A4VSO pump to a greener direction:

· Biodegradable hydraulic oil adaptation : Optimized design to adapt to environmentally friendly media

· Leakage Control Technology : The Standard for Zero External Leakage

· Noise suppression : Reduce noise by another 3-5dB through structural optimization

· Recyclable design : Improve material recovery rate and disassembly convenience

In the future, the hydraulic systems in forging shops will be cleaner, quieter and in harmony with the environment.

7.5 Standardization and Modular Development

To reduce costs and shorten delivery time, the A4VSO pump will enhance:

· Interface standardization : simplifies system integration and reduces customization requirements

· Modular design : meet diverse needs by combining standard modules

· Software configuration : Function adjustment is achieved through parameter setting rather than hardware changes

· Global unified platform : consistent product technical specifications in different regions

These trends will enable forging equipment manufacturers to obtain the most suitable hydraulic solution more quickly and economically.

8. Conclusion and Recommendations

8.1 Technical Summary

Through a comprehensive analysis of the A4VSO axial piston variable pump in the forging solution, the following technical conclusions can be drawn:

1. High pressure and high efficiency : A4VSO series has a rated pressure of 350Bar and a peak pressure of 400Bar , and a variety of variable control methods to perfectly match the forging process requirements.

2. Significant energy saving : Compared with traditional quantitative pump systems, typical energy saving is 30-50%, and the investment payback period is short

3. Reliable and durable : Aviation-grade bearings and optimized friction pair design ensure long life in harsh forging environments

4. Flexible adaptation : displacement range from 40 to 1000ml/r, multiple control modes to meet the needs of different forging equipment

5. Intelligent Foresight : Possessing the technical foundation for intelligent and networked development to meet the needs of future smart factories

8.2 Selection and application recommendations

Based on the analysis of this study, the following recommendations are made to forging equipment manufacturers and users:

New product design:

· Priority is given to the A4VSO variable pump solution, especially the 125-355ml/r specification

· Select the control method according to the process characteristics. EO2 electrical control is recommended for complex processes.

· Reasonable design of hydraulic system to give full play to the advantages of variable displacement pump

Modification of existing equipment:

· Evaluating the economics of converting a fixed displacement pump system to an A4VSO variable displacement pump

· Prioritize the transformation of high energy consumption and high load rate equipment

· Consider phased renovation to reduce investment risk

Use and maintenance:

· Strictly maintain oil cleanliness NAS9 level

· Regular monitoring of pump status and preventive maintenance

· Establish a complete operation and maintenance file

8.3 Industry Development Outlook

With the advancement of the "carbon peak and carbon neutrality" goals, the forging industry will face greater pressure to improve energy efficiency, and the market share of high-efficiency hydraulic axial piston pumps such as A4VSO will further increase:

· High-end market : Intelligent and networked variable pumps will become standard

· Mid-end market : Accelerating the transition from fixed-displacement pumps to variable-displacement pumps

· Emerging fields : such as precision forging, isothermal forging, etc., which have growing demand for high-performance pumps

It is expected that in the next five years, the penetration rate of variable displacement pumps in the hydraulic systems of forging equipment will increase from the current approximately 45% to more than 65%, among which the A4VSO series will maintain its technological leadership.

8.4 Final Recommendations

For decision makers seeking to upgrade or build a new hydraulic system for forging equipment, we strongly recommend:

1. Priority will be given to evaluating the A4VSO variable pump solution , especially the 180-355ml/r specification products

2. Choose an experienced system integrator to ensure design optimization

3. Invest in operator maintenance training to get the most out of your equipment

4. Establish long-term technical cooperation relationship and track product innovation

By adopting the proven and efficient solution of A4VSO axial piston variable displacement pump, forging companies will achieve significant energy savings, quality improvement and enhanced competitiveness, laying a solid foundation for sustainable development .