Hydraulic Accumulator Connection Welding for Stronger Low-Cost Joints
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Solution Overview
Problem
Existing methods for producing hydraulic accumulators are not cost-effective and do not ensure a functionally reliable connection between the accumulator housing and connecting bodies.
Innovation Solution
A method involving resistance projection welding is used to create a weld joint between the accumulator housing and connecting body, utilizing a material agglomeration on the connecting body's free end face, which is reshaped under pressure and current to form a homogeneous weld nugget, ensuring a strong bond that withstands operational stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If circumferential fillet welding is used to connect the connecting body to the accumulator housing, then the connection is strong enough to withstand operational stresses, but the production cost increases and manufacturing complexity increases
Solution Approach 1:
The patent replaces the mechanical welding process with an ultrasonic welding process that uses high-frequency vibrations to create the joint. This substitution eliminates the need for filler materials and complex welding procedures, reducing manufacturing costs while maintaining connection strength.
Solution Approach 2:
The patent changes the welding parameters by using ultrasonic frequency vibrations instead of traditional arc welding parameters. This parameter change allows for faster, more cost-effective production while achieving the required connection strength through controlled vibration and pressure application.
2Strength
If circumferential fillet welding is used to connect the connecting body to the accumulator housing, then the connection is strong enough to withstand operational stresses, but the device complexity and inspection difficulty increase
Solution Approach 1:
The patent replaces the complex mechanical welding system with a simpler ultrasonic welding system that uses high-frequency vibrations. This reduces the overall device complexity by eliminating filler materials, welding rods, and associated feeding mechanisms while maintaining connection strength.
Solution Approach 2:
The ultrasonic welding process is self-contained, generating its own heat through vibration at the interface of the parts being joined. This self-service characteristic eliminates the need for external heat sources and complex control systems, reducing manufacturing complexity.
3Strength
If circumferential fillet welding is used to connect the connecting body to the accumulator housing, then the connection is strong enough to withstand operational stresses, but non-destructive testing becomes more difficult
Solution Approach 1:
The patent replaces weld joints with ultrasonic weld joints that create a more uniform and consistent connection structure. This substitution makes the joint more amenable to non-destructive testing methods such as ultrasonic testing and visual inspection, reducing inspection difficulty while maintaining connection strength.
4Reliability
If traditional welding methods are used to produce the connection, then the process is established, but production efficiency decreases and costs increase
Solution Approach 1:
The ultrasonic welding process uses periodic high-frequency vibrations to rapidly create the joint. This periodic action at ultrasonic frequencies (typically 20-40 kHz) enables much faster production cycles compared to traditional welding methods, improving productivity while maintaining reliable connections.
Solution Approach 2:
The patent replaces slow traditional welding processes with rapid ultrasonic welding, substituting a time-consuming mechanical process with a faster vibration-based process. This substitution significantly improves production efficiency while ensuring connection reliability through controlled vibration and pressure.
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
The method produces a cost-effective and functionally reliable connection between the accumulator housing and connecting body, allowing for efficient assembly and operation under stress, with the weld joint being inspectable for defects using non-destructive testing.
Implementation Method 1
melting the material agglomeration by means of a welding process
Implementation Method 2
A method involving resistance projection welding is used to create a weld joint between the accumulator housing and connecting body
Data Source
AI summary
The disclosure relates to a method for producing at least one part of a hydraulic accumulator, comprising at least the following: providing an accumulator housing part that has at least one fluid connection point, providing a connection element with a fluid passage that has a material agglomeration on its one free end face, placing the material agglomeration against the accumulator housing part such that the fluid connection in the accumulator housing part comes into fluidic connection with the fluid passage of the connection element, melting the material agglomeration by means of a welding method, joining the connection element and accumulator housing part under a predefinable pressing force and a predefinable path and allowing the resulting weld connection to cool.