Integrated Electro-Hydraulic Bolt Elongation Without External Hoses
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing hydraulic systems for bolt elongation tools are bulky, unsafe due to high pressure, and unsuitable for accessing difficult or dangerous locations, as they require external pumps and hoses that can fail, leading to accidents and inefficiencies.
Innovation Solution
A compact electro-hydraulic actuator system with an electric motor that generates hydraulic pressure directly within the tool, eliminating the need for external hoses and pumps, allowing for precise and safe bolt elongation with a plug-and-play design and security valves to prevent leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If an external hydraulic pump is used to supply high pressure (over 1000 MPa) to the bolt elongation tool, then sufficient bolt elongation can be achieved, but the system becomes bulky, unsafe, and unsuitable for difficult-to-access locations
Solution Approach 1:
The patent integrates the hydraulic pressure generator directly into the bolt elongation tool, merging previously separate components (external pump and tool) into a single integrated unit. This eliminates the need for external hoses and bulky equipment while maintaining the required high pressure output for bolt elongation.
Solution Approach 2:
The patent extracts the hydraulic pressure generation function from the external system and embeds it within the tool itself. By taking out the pressure generation capability and integrating it internally, the system becomes self-contained, portable, and suitable for difficult-to-access locations without sacrificing pressure output.
2Force
If external hoses are used to connect the hydraulic pump to the bolt elongation tool, then hydraulic pressure can be transmitted, but the connection is vulnerable to failure, leakage, and accidents
Solution Approach 1:
By integrating the hydraulic pressure generator directly into the tool, the patent eliminates the intermediate connection (hoses) that was vulnerable to failure. The merging of components removes the weak link in the pressure transmission path, thereby improving reliability and safety.
3Force
If a standardized high-pressure hydraulic system is used, then sufficient pressure can be generated, but the system is oversized and cannot be adapted for specific bolt elongation applications
Solution Approach 1:
The patent applies local quality by designing a hydraulic pressure generator specifically tailored for bolt elongation applications. Rather than using a generic high-pressure system, the generator is customized with appropriate pressure ranges, flow rates, and physical dimensions optimized for the specific requirements of bolt elongation, improving both adaptability and efficiency.
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 system provides a safe, compact, and efficient means to apply tailored hydraulic pressure for bolt elongation, ensuring high-quality tightening with reduced risk of accidents and increased system longevity, suitable for manual or automated use in challenging environments.
Implementation Method 1
the hydraulic actuator is an electro-hydraulic actuator comprising an electric motor built to generate the power of the electro-hydraulic actuator
Implementation Method 2
the actuator piston is built to supply, with one stroke of an actuator stroke height of the actuator piston, at least the amount of hydraulic pressure that is needed to move the tool piston
Data Source
AI summary
System for supplying hydraulic pressure to a bolt elongation tool, comprising the bolt elongation tool with at least one pressure chamber and a tool piston, a hydraulic medium supply system and a hydraulic actuator with an actuator cylinder housing an actuator piston. The actuator cylinder is attached to the at least one pressure chamber, wherein the hydraulic actuator is an electro-hydraulic actuator comprising an electric motor built to generate the power of the electro-hydraulic actuator, and wherein the actuator piston is built to supply, with one stroke of an actuator stroke height of the actuator piston, at least the amount of hydraulic pressure that is needed to move the tool piston for the amount of one tool stroke height of the tool piston.