Electro Press Actuator for Connecting Rod Cracking
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Solution Overview
Problem
Existing machines for cracking connecting rods face challenges with hydraulic systems, which are not clean, lack stability and control, and are energy-intensive, while mechanical systems require complex adaptations for different types of connecting rods.
Innovation Solution
A machine using an electro press with a servomotor to actuate an expandable element, allowing for precise control of force, speed, and position, and featuring a two-step actuation process to accelerate the first actuator part before displacing the second, ensuring efficient and high-quality cracking without the need for an oversized motor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If hydraulic systems are used to actuate the expandable element, then the cracking process can be performed with sufficient force, but the system becomes energy-intensive, less clean, and lacks stability and control
Solution Approach 1:
The patent replaces the hydraulic actuation system with a mechanical actuation system using an electric motor coupled to a ball screw mechanism. This substitution eliminates the need for hydraulic fluid and pumps, reducing energy consumption and improving environmental cleanliness while maintaining precise control and stability. The mechanical transmission through the ball screw converts rotational motor motion into linear actuator motion with high efficiency.
2Force
If hydraulic systems are used to actuate the expandable element, then the cracking process can be performed with sufficient force, but the system lacks stability and control
Solution Approach 1:
The patent replaces the hydraulic actuation system with a mechanical actuation system using an electric motor coupled to a ball screw mechanism. This substitution eliminates the need for hydraulic fluid and pumps, reducing energy consumption and improving environmental cleanliness while maintaining precise control and stability. The mechanical transmission through the ball screw converts rotational motor motion into linear actuator motion with high efficiency.
Solution Approach 2:
The patent incorporates sensors to detect the position and speed of the actuators, with this information fed back to a control unit. The control unit processes the sensor signals and adjusts the motor actuation accordingly, enabling closed-loop control that ensures precise positioning and speed control during the cracking process, thereby improving stability and reliability.
3Use of energy by moving object
If mechanical systems are used to actuate the expandable element, then energy consumption is reduced, but complex adaptations are required for different types of connecting rods
Solution Approach 1:
The patent employs programmable control of the motor actuation parameters (speed, force, position) to adapt the cracking process to different connecting rod types. The control unit stores multiple actuation programs that can be selected based on the specific rod type, allowing dynamic adjustment of process parameters without physical modifications to the machine structure.
Solution Approach 2:
The patent utilizes the ability to change operational parameters (actuator speed, force, position) through software control to accommodate different connecting rod types. The control unit allows programming of different actuation sequences and parameters, enabling the same mechanical system to handle various rod configurations by simply changing the control program rather than the hardware.
4Device complexity
If a single actuator is used to expand the expandable element, then the system is simpler, but insufficient force and control are achieved during cracking
Solution Approach 1:
The patent divides the actuation system into two separate actuators: a first actuator that expands the expandable element to initiate cracking, and a second actuator that applies additional force to complete the separation. This segmentation allows each actuator to be optimized for its specific function, with the first actuator providing controlled expansion and the second actuator delivering the necessary force to finalize the cracking process, thereby achieving sufficient total force while maintaining reasonable system complexity.
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 improved quality and efficiency in cracking connecting rods by maintaining a constant velocity during the cracking process, reducing the risk of deformations and allowing for easy adaptation to different types of connecting rods without hardware changes, ensuring repeatability and consistency in product quality.
Implementation Method 1
an electro press with a servomotor to actuate an expandable element, allowing for precise control of force, speed, and position
Implementation Method 2
expanding element arranged to be inserted into a bore in the big end of the connecting rod so as to allow for splitting of the connecting rod into a rod part and a cap part by expanding the expandable element
Implementation Method 3
a two-step actuation process to accelerate the first actuator part before displacing the second, ensuring efficient and high-quality cracking without the need for an oversized motor
Data Source
AI summary
The machine for cracking a connecting rod comprises an electro press with an electric motor (400) for actuating an expandable element. The electro press comprises a first S actuator part (410) and a second actuator part (430) arranged so that when the first actuator part is driven by the electric motor (400) from a first position to a second position, (a) the first actuator part (410) is first driven by the electric motor (400) from said first position (FIG. 12A) to an intermediate position (FIG. 12B), without displacing the second actuator part (430), and (b) subsequently the first actuator part (410) is further driven by the electric motor (400) from said intermediate position (FIG. 12B) to said second position (FIG. 12C), displacing the second actuator part from a non-expanding position to an expanding position.