Clamp Device Valve Mechanism for Malfunction Detection
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Solution Overview
Problem
Conventional clamp devices fail to detect malfunctions such as idle clamping, excessive expansion of engagement members, and broken clamping rod components due to their design, where the annular pressure-receiving member cannot effectively move downward to detect these issues, leading to undetected malfunctions and potential defects.
Innovation Solution
A clamp device with a valve mechanism actuated by the piston rod, which moves to an abnormal stroke region to open or close the valve mechanism, allowing pressurized air to flow out and detect changes in pressure, enabling the detection of malfunctions through a pressure switch, even in cases of idle clamping or broken components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the annular pressure-receiving member is used as the actuating portion for malfunction detection, then the structure is simple and compact, but it cannot detect malfunctions in idle clamping or when the clamping rod breaks
Solution Approach 1:
The actuating portion is segmented into two independent components: the annular pressure-receiving member and the piston rod. The piston rod is modified to include a protruding actuating portion that independently actuates the valve mechanism, separating the detection function from the pressure-receiving function. This allows the system to detect malfunctions even when the annular pressure-receiving member remains stationary.
Solution Approach 2:
The piston rod serves as an intermediary element that transmits the abnormal downward movement to the valve mechanism. The actuating portion on the piston rod directly contacts and moves the valve member, creating a reliable detection path that bypasses the annular pressure-receiving member's limitation in idle clamping scenarios.
2Productivity
If the engagement members are expanded by the wedge face during idle clamping, then the clamping action is performed, but the annular pressure-receiving member cannot move downward to detect the malfunction
Solution Approach 1:
The detection function is segmented from the annular pressure-receiving member and assigned to the piston rod's actuating portion. This allows the engagement members to be expanded during idle clamping while the piston rod independently detects the abnormal condition by moving downward and actuating the valve mechanism.
Solution Approach 2:
The valve mechanism provides immediate feedback when the piston rod moves downward during idle clamping. The pressure switch detects the valve's opening state, providing real-time feedback about the abnormal condition, enabling the system to distinguish between normal and idle clamping operations.
3Reliability
If the piston moves downward to the locking margin stroke region beyond the lock stroke region, then the malfunction due to slip is detected, but the same mechanism fails to detect idle clamping or broken components
Solution Approach 1:
The piston rod's actuating portion serves multiple functions: it actuates the valve mechanism for slip detection (when movement occurs beyond lock stroke) and for idle clamping detection (when movement occurs during expansion). This universal actuating mechanism covers all malfunction scenarios through a single design element.
Solution Approach 2:
The valve mechanism provides universal feedback for all abnormal downward movements of the piston rod, regardless of the cause (slip, idle clamping, or broken components). The pressure switch continuously monitors the valve state, providing comprehensive feedback coverage for all malfunction types.
4Reliability
If the valve mechanism is actuated by the piston rod in the abnormal stroke region, then malfunction detection is enabled, but the device requires additional space for the valve mechanism
Solution Approach 1:
The valve mechanism is nested within the existing housing structure, utilizing the annular space between the piston rod and the housing wall. The valve member is positioned in the annular space, and the actuating portion of the piston rod extends into this space to directly actuate the valve, eliminating the need for additional external space.
Solution Approach 2:
The valve mechanism is arranged in the radial dimension rather than requiring additional axial or lateral space. The valve member is positioned radially outward from the piston rod, utilizing the annular cross-sectional space already present in the cylindrical housing, thereby maintaining a compact overall dimensions.
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 clamp device effectively detects malfunctions by changes in pressure, ensuring operational safety and preventing damage from undetected issues like excessive expansion or broken parts, and allows for compact design by utilizing the valve mechanism in the housing.
Implementation Method 1
allowing pressurized air to flow out and detect changes in pressure
Implementation Method 2
a wedge face provided in the upper part of the clamping rod causes the engagement members retained at the raised position by the annular pressure-receiving member to move radially outward
Implementation Method 3
upward hydraulic pressure exerted on an annular pressure-receiving member
Data Source
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AI summary
A plurality of engagement members (20), inserted in a hole in an object to be fixed, which are capable of gripping an inner circumferential surface of the hole are provided, and a wedge face (32) of a clamping rod (15) is engaged on an inner circumference of the engagement member (20) from an upper side. An upper part of a piston rod (55) protruding upward from a piston body (54) of a piston (12) is coupled to a lower part of the clamping rod (15). The engagement member (20), the clamping rod (15), and the piston (12) are provided in a housing (2). An annular valve member (78) is provided between the housing (2) and the piston rod (55). When the piston (12) has moved to a lower-limit region in a lock direction, an actuating portion (89) of the piston rod (55) causes the valve member (78) via an actuated portion (99) of the valve member (78) to be opened downward.