3D-Printed Bellows Separator for Uniform Stress Distribution
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Solution Overview
Problem
Existing manufacturing processes for bellows in hydraulic accumulators result in high manufacturing effort and increased likelihood of material failure due to unfavorable stress distribution, particularly at deflection points, leading to reduced service life.
Innovation Solution
The use of 3D printing processes, such as electron beam melting or selective laser melting, to create a single diaphragm separator with arcuate deflection points and acute angles between adjacent diaphragm surfaces, achieving an isotensoid stress profile and uniform stress distribution, reducing material thickness where necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional hydraulic forming or mechanical roll forming processes are used to manufacture bellows pleats individually, then manufacturing precision can be maintained, but manufacturing effort and time increase significantly
Solution Approach 1:
The patent merges multiple individually manufactured bellows pleats into a single integral diaphragm structure. Instead of producing each pleat separately through hydraulic forming or mechanical roll forming, the invention creates one continuous diaphragm that forms multiple pleats as a unified structure, thereby eliminating repetitive manufacturing steps and reducing overall manufacturing effort and time.
Solution Approach 2:
The patent segments the diaphragm into multiple bellows pleats within a single integral structure. By designing the diaphragm with predefined pleat formations that can be created in one manufacturing process, each pleat functions as a segmented unit while maintaining structural continuity, thus achieving both functional segmentation and manufacturing efficiency.
2Strength
If bellows pleats are formed with arcuate deflection points using traditional processes, then structural integrity is maintained, but unfavorable stress distribution occurs leading to material failure
Solution Approach 1:
The patent applies local quality by varying the geometry of deflection points specifically in areas where stress concentration occurs. Instead of uniform arcuate shapes throughout, the invention modifies the deflection point geometry locally to achieve more favorable stress distribution in critical areas while maintaining overall structural integrity.
Solution Approach 2:
The patent utilizes curvature optimization by carefully designing the deflection point geometry with specific radii and arc shapes. By optimizing the curvature characteristics of deflection points, the invention reduces stress concentration and improves stress distribution, thereby enhancing both structural integrity and service life.
3Ease of manufacture
If a single integral diaphragm is manufactured using 3D printing processes, then manufacturing simplicity and cost-effectiveness improve, but new manufacturing technologies must be implemented
Solution Approach 1:
The patent replaces traditional mechanical forming processes (hydraulic forming, mechanical roll forming) with 3D printing technology. This substitution enables the manufacturing of complex integral diaphragm structures with optimized deflection point geometries that would be difficult or impossible to achieve with conventional mechanical processes, thereby simplifying the overall manufacturing approach despite introducing advanced technology.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for simple, cost-effective manufacturing and prevents material failure, ensuring long-lasting operation with improved stress distribution and response behavior under dynamic conditions.
Implementation Method 1
The use of 3D printing processes, such as electron beam melting or selective laser melting
Implementation Method 2
The use of 3D printing processes, such as electron beam melting or selective laser melting
Data Source
AI summary
Separator and hydraulic accumulator having such a separator. A separator, in particular for a hydraulic accumulator, such as a bellows accumulator, which is produced by a 3D printing process, consisting of one single diaphragm, which, when viewed in cross section, is deflected in an arcuate shape to form a multitude of bellows pleats at deflection points, which delimit the bellows pleats on the outside and the inside, and in that, to obtain an isotensoid or essentially isotensoid stress profile in the diaphragm, the notional extensions of the diaphragm surfaces adjacent to each deflection point form an acute angle with each other, at least in an initial state.