Cylinder Pipe Connection Structure With Calottes and Annular Weld
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Solution Overview
Problem
Existing methods for connecting a cylinder pipe to a connection piece, such as screw connections and welding, face challenges including material inefficiency, high production costs, risk of contamination, and structural weakening, which affect mechanical strength and cleanliness.
Innovation Solution
A cylinder pipe assembly featuring cold-formed concave embossed calottes that create a structural consolidation zone, a punched connection bore hole enclosed by the calottes, and an annular weld seam for a durable and gap-free connection, allowing for efficient and cost-effective production with reduced material waste and enhanced mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If screw connections are used with internal threads in the cylinder pipe, then the connection mechanical strength is improved, but the wall thickness must be increased or extensive machining is required
Solution Approach 1:
A connection piece with an L-shaped cross-section serves as an intermediary component. It features a first leg with external threads that engage with internal threads in the cylinder pipe, and a second leg that connects to the fitting. This intermediary structure distributes the connection load and eliminates the need for complex internal threading in the cylinder pipe wall.
Solution Approach 2:
The connection system is segmented into distinct functional components: the cylinder pipe, the connection piece, and the fitting. The connection piece acts as a separate modular element that bridges the cylinder pipe and fitting, allowing each component to be optimized independently for its specific function.
2Strength
If welding processes are used to connect the connection piece to the cylinder pipe, then the connection strength is improved, but the cylinder pipe material undergoes structural changes that negatively affect strength
Solution Approach 1:
The connection piece is designed with differentiated local properties: the first leg portion has external threads for engaging the cylinder pipe, while the second leg portion is designed for welding to the fitting. This local differentiation allows the welding to be concentrated in a specific area (the second leg) rather than affecting the entire cylinder pipe structure, thereby preserving the overall material strength and reliability.
3Productivity
If bore holes are produced by drilling or milling for pressure medium connection, then the pressure medium flow is enabled, but chips and dust accumulate in the cylinder interior and contaminate the oil
Solution Approach 1:
The harmful drilling/milling operation is extracted and replaced with a punching operation. The connection bore hole is punched through the cylinder pipe wall, and the removed material (slug) is extracted as a single piece rather than being dispersed as chips and dust. This eliminates the contamination problem while maintaining the pressure medium flow function.
4Productivity
If the connection bore hole is punched through the cylinder pipe, then the pressure medium flow is enabled, but the connection area becomes structurally weakened
Solution Approach 1:
The structural consolidation zone is created as a preliminary action before the connection bore hole is punched. This pre-strengthening of the cylinder pipe wall material in the connection area ensures that when the bore hole is subsequently created, the surrounding structure has already been prepared to withstand the structural weakening effect, maintaining overall strength while enabling efficient punched hole production.
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 solution provides a high-quality, cost-effective, and durable cylinder pipe assembly with improved mechanical strength, reduced contamination risk, and efficient production, ensuring a homogeneous pressure medium flow and prolonged component lifespan.
Implementation Method 1
the calottes are designed as cold-formed concave embossed portions and create a structural consolidation zone in a forming area between the calottes
Implementation Method 2
the pressure medium is led in or out laterally through the cylinder pipe... The connection portion in turn has an outer shell calotte, which is arranged on a cylinder pipe outer shell, and an inner shell calotte, which is arranged on a cylinder pipe inner shell
Implementation Method 3
an annular weld seam for a durable and gap-free connection
Data Source
AI summary
A cylinder pipe assembly has a connection piece, and cylinder pipe with a main body and a connection portion. The connection portion has an outer shell calotte on a cylinder pipe outer shell and an inner shell calotte on a cylinder pipe inner shell, a connection hole, and a structural consolidation zone surrounds the connection hole. The calottes are concave embossed portions. The structural consolidation zone is arranged in a region between the calottes. The connection hole is punched and passes through the calottes. The connection piece is arranged at the connection portion and has a pressure medium tube and a connecting portion with an annular axial boundary contour that with an annular mating surface defines an annular contact surface. The cylinder pipe and the connection piece are connected in a bonded manner by an annular weld seam, and the weld seam defines a sealing plane.