Axial Piston Machine Insert Ring Segmentation
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Solution Overview
Problem
The existing axial piston machines face issues with damage and deformation due to high hydraulic pressure, particularly in the transition zones of the cup-shaped housing where shrinkage cavities can occur, leading to reduced machine life, especially in dual axial piston machines.
Innovation Solution
The axial piston machine incorporates an insert ring that serves as both a support for the drive shaft and a high-pressure duct section, optimized in terms of material and design to manage pressure loading, allowing for a thinner housing with reduced manufacturing complexity and avoiding material accumulation issues during casting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the housing is made from spheroidal graphite iron with a cup-shaped design, then the housing can be produced through casting, but shrinkage cavities occur in the transition zone from the circumferential wall to the bottom region, leading to damage or deformation under high hydraulic pressure
Solution Approach 1:
The housing is divided into two distinct parts: a cup-shaped housing made from spheroidal graphite iron for ease of casting, and a separate insert ring made from steel or light alloy that is inserted into the housing. This segmentation allows each part to be optimized independently for its specific requirements.
Solution Approach 2:
The solution uses composite construction by combining different materials in the housing system. The housing uses spheroidal graphite iron for casting ease, while the insert ring uses steel or light alloy for superior pressure resistance. This composite approach resolves the contradiction between ease of manufacture and pressure resistance.
2Reliability
If the housing wall is made thicker to prevent damage from shrinkage cavities, then pressure resistance improves, but the overall volume and manufacturing complexity increase
Solution Approach 1:
By separating the housing into two parts, the insert ring can be made with optimized thickness for pressure resistance without increasing the overall housing volume. The insert ring provides the necessary structural strength in the critical pressure zones.
Solution Approach 2:
The insert ring provides enhanced pressure resistance specifically in the critical regions where shrinkage cavities occur, such as the transition zones and high-pressure duct areas. This localized reinforcement maintains overall housing compactness while improving pressure resistance where needed.
3Adaptability or versatility
If the housing is designed with a dual cup configuration for dual axial piston machines, then functionality is improved, but casting problems become more severe and difficult to overcome
Solution Approach 1:
The dual cup housing is segmented into separate components, with each cup being cast independently using spheroidal graphite iron, and separate insert rings being installed in each cup. This segmentation simplifies the casting process compared to manufacturing a single complex dual cup housing.
Solution Approach 2:
The dual axial piston machine uses composite construction with separate housing cups and insert rings. This allows each component to be optimized independently, making the overall system easier to manufacture while maintaining the dual piston configuration.
4Ease of manufacture
If the housing is made thinner to reduce material usage and manufacturing complexity, then production cost decreases, but pressure resistance is reduced
Solution Approach 1:
The housing is segmented into a thin-walled cup-shaped housing and a separate insert ring. The thin housing reduces material usage and manufacturing complexity, while the insert ring provides the necessary pressure resistance in critical areas.
Solution Approach 2:
The insert ring provides localized pressure resistance in the critical regions where high hydraulic pressure acts on the housing, such as the transition zones and high-pressure duct areas. This allows the overall housing to remain thin while maintaining sufficient pressure resistance.
Data Source
AI summary
An axial piston machine includes a housing having a casting which is optimized with respect to casting. An insert ring which is optimized with respect to a pressure load is formed in the bottom of the housing. The insert ring is configured to be used with such an axial piston machine.