Floating Piston Actuator for Side Load Mitigation
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Solution Overview
Problem
Hydraulic cylinders face stress and potential failure due to side loads that cause misalignment and bending moments, which existing solutions have not adequately addressed, leading to premature wear and damage.
Innovation Solution
A floating piston system is implemented, where the piston is attached to the rod with a loose connection allowing clearance, enabling the piston to move relative to the rod and reduce stress on the outer diameter, thereby accommodating side loads and minimizing friction and wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the piston is rigidly attached to the rod, then the connection strength is improved, but the stress from side loads increases causing misalignment and potential failure
Solution Approach 1:
The piston is designed to float dynamically on the rod rather than being rigidly fixed. The clearance between the piston and rod allows relative movement, enabling the piston to self-align and accommodate side loads dynamically during operation, thus reducing stress while maintaining connection strength
2Reliability
If perfect alignment is achieved, then side loading is reduced, but manufacturing complexity and cost increase
Solution Approach 1:
The floating piston design enables the system to self-correct alignment issues during operation. The clearance allows the piston to naturally float into the optimal position, eliminating the need for complex pre-alignment procedures or expensive precision manufacturing, while still achieving reduced side loading
3Reliability
If the piston is loosely connected to the rod, then stress from side loads is reduced, but the connection stability deteriorates
Solution Approach 1:
The connection parameters are optimized by introducing a specific clearance range rather than rigid fixation. This parameter change allows the piston to move freely enough to accommodate side loads and maintain stability, while the mating structure geometry ensures the connection remains stable and functional
Data Source
AI summary
An actuator is provided. The actuator includes: a housing having an interior elongated hole; a rod dimensioned to fit in the elongated hole; a piston dimensioned to fit in and move along the elongated hole while connected to the rod; mating structure located on at least one of the piston and rod, the mating structure configured to allow the rod to attach to the piston in a manner to create clearance between the rod and the piston to allow the rod and piston to move with respect to each other. A method of attaching a piston to a rod in an actuator may also be provided. The method may include: fitting the piston to the rod; providing a clearance between the piston and the rod; fastening the piston to the rod in a loose manner as to preserve the clearance and allow the piston to move with respect to the rod.