DTH Hammer Fluid Flow System with Parallel Recess Channels
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Solution Overview
Problem
Existing pressurized fluid flow systems for DTH hammers suffer from reduced power and energy conversion efficiency due to alignment issues, dissipative forces, and complex manufacturing processes, leading to increased fluid consumption and reduced durability.
Innovation Solution
A pressurized fluid flow system with equal diameter outer sliding surfaces and solid piston design, featuring a cylinder with parallel supply and discharge channels defined by recesses, eliminating the need for holes and channels, which enhances thrust areas and simplifies manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional pressurized fluid flow systems are used with alignment issues and complex manufacturing, then manufacturing flexibility is improved, but power and energy conversion efficiency are reduced
Solution Approach 1:
The system segments the fluid flow paths into distinct supply channels and discharge channels within the cylinder, allowing independent optimization of each flow path while maintaining overall system simplicity and manufacturing flexibility
Solution Approach 2:
The piston serves multiple functions simultaneously: it acts as a sealing element, a fluid distribution valve, and a thrust generation surface, eliminating the need for separate alignment mechanisms and complex manufacturing while maximizing power transmission
2Ease of manufacture
If traditional pressurized fluid flow systems are used with alignment issues and complex manufacturing, then manufacturing flexibility is improved, but energy conversion efficiency is reduced
Solution Approach 1:
The invention extracts and eliminates dissipative forces and alignment issues from the system by using a simplified cylinder-piston design with recess-defined channels, removing sources of energy loss while maintaining manufacturing flexibility
Solution Approach 2:
The supply channels and discharge channels are merged into a single cylindrical structure with recesses, eliminating the need for separate alignment mechanisms and reducing energy loss from misalignment while keeping the system manufacturable
3Power
If equal diameter outer sliding surfaces and solid piston design are used, then thrust areas are increased and energy conversion efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The recesses are created only in the specific locations where fluid channels are needed on the piston surface, maintaining simplicity in non-critical areas while providing the necessary complexity only where required for fluid distribution
Solution Approach 2:
The recess pattern is designed as a simple geometric replication that can be manufactured using standard copying or molding techniques, reducing manufacturing complexity while achieving the desired channel configuration for optimal thrust area
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 configuration increases the front and rear thrust areas of the piston, improving energy conversion efficiency and reducing manufacturing costs while maintaining durability and reliability.
Implementation Method 1
the piston effects a reciprocating movement due to the change in pressure of the pressurized fluid contained in two main chambers, a front chamber and a rear chamber
Implementation Method 2
the drill bit being in contact with the front chamber and adapted to receive the impact of the front end of the piston
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
A pressurized fluid flow system for a normal circulation down-the-hole hammer comprises a cylinder coaxially disposed in between an outer casing and a piston which reciprocates due to changes in pressure of pressurized fluid contained inside a front chamber and rear chamber located at opposites sides of the piston, the supply/discharge of fluid to/from these chambers being conducted through sets of supply and discharge channels defined by recesses on the outer surface of the cylinder and arranged in a parallel, the fluid flowing in and out of the front and rear chambers being controlled solely by the relative overlap of the piston and the cylinder and channeling of the flow of fluid below the inner surface of the cylinder and above the outer surface of the piston. A hammer provided with this system comprises a drill bit with one or more flushing passages.