The control system of the HPHT Hydraulic Cubic Presssignificantly reduces carbide anvil consumption by optimizing pressure regulation, fault protection, and process parameter matching. Below is a detailed analysis of the mechanisms and supporting data:
1. Dynamic Pressure Compensation Reduces Pressure Fluctuations
Control Method: A lower pressure threshold (e.g., activating a small pump when pressure drops 0.15 MPa below the set value) and an upper limit (e.g., stopping at 0.05 MPa above) maintain dynamic balance.
Effect: Pressure fluctuations are confined to ±0.05 MPa, minimizing mechanical wear on anvils caused by abrupt pressure changes.
2. Multi-Parameter Protection System Cuts Abnormal Losses
Absolute Protection: Immediate shutdown upon exceeding limits for pressure, current, or voltage prevents equipment failures (e.g., thyristor breakdown, hydraulic leaks) from damaging anvils.
Relative Protection: Monitors pressure change rates and resistance deviations to preemptively flag material or system anomalies.
Data Comparison:
Relay-based control: Anvil consumption at 2 kg/10k carats, with 18% loss attributed to failures.
Automated control with enhanced protection: Consumption drops to 0.5 kg/10k carats, failure-related losses reduced to 6.9%.
3. Alarm System Mitigates Accident-Induced Losses
Electrical Faults: Immediate shutdown for issues like burnt plugs or insulation cap damage prevents anvil overload.
Hydraulic Faults: Pressure anomalies trigger停机 to address leaks or valve failures.
Material Defects: Detects resistance/voltage abnormalities to reduce anvil impact from flawed synthesis blocks.
4. Automated Process Optimization
T-P-t Coordination: Industrial computers precisely control temperature (T), pressure (P), and time (t) curves to avoid anvil overload or uneven wear from parameter mismatches.
Result: One operator can manage four presses, reducing human-error-induced.
5. Future Technical Directions
Electro-Hydraulic Proportional Control: Enables precise adjustment of six-cylinder displacement and ultra-high pressure to further reduce mechanical shocks.
Frequency Conversion Technology: Replaces small pumps to eliminate pressure surge during compensation, enabling fuzzy PID control.
Summary: Upgrades in the HPHT Hydraulic Cubic Press control system (dynamic compensation, multi-parameter protection, automated process matching) reduced anvil consumption from 2 kg/10k carats to 0.5 kg/10k carats.