Hydraulic Accumulator Joining via Electromagnetic Pulse
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Solution Overview
Problem
Current methods for manufacturing hydraulic accumulators, particularly diaphragm accumulators, face challenges such as surface damage, uneven deformation, and tightness issues due to the use of high-force tools for form-fitting connections, leading to potential geometric imbalances and strength problems.
Innovation Solution
The implementation of a non-contact electromagnetic pulse joining process that applies uniform forces to deform components radially, eliminating the need for clamping rings and allowing for a material connection, thereby ensuring reliable tightness and rotational symmetry without surface damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If tools with considerable forces are used to produce form fit by reshaping components, then the components can be connected in a form-fitting manner, but the outer surface of the components is damaged with scratches, dents or scratches
Solution Approach 1:
The patent replaces conventional mechanical pressing tools with electromagnetic pulse joining technology. A coil generates a magnetic field that induces eddy currents in the conductive component, creating Lorentz forces for deformation without mechanical contact. This substitution of mechanical systems with electromagnetic fields achieves form-fitting connections while eliminating surface damage from tool contact.
Solution Approach 2:
The patent introduces an electromagnetic field as an intermediary between the tool and the component. The coil generates a magnetic field that serves as a mediator to transmit force to the conductive component through induced eddy currents. This intermediary approach allows force transmission without direct mechanical contact, preventing surface damage while achieving the desired deformation.
2Stability of the object's composition
If tools act on components to create form fit, then components can be joined, but uneven and out-of-round deformation occurs leading to geometric imbalance
Solution Approach 1:
The patent replaces mechanical pressing tools that apply uneven contact forces with electromagnetic pulse joining that generates uniformly distributed Lorentz forces through induced eddy currents. The electromagnetic field naturally distributes forces evenly around the circumferential direction, preventing geometric imbalance and maintaining rotational symmetry during deformation.
Solution Approach 2:
The patent changes the physical state and distribution of forces by using electromagnetic fields instead of mechanical contact. The pulsed electromagnetic field creates transient eddy currents that generate Lorentz forces with uniform spatial distribution, fundamentally changing how forces are applied to achieve symmetric deformation without the geometric imbalances caused by mechanical tool contact.
3Ease of manufacture
If welding processes are used to seal housing shells, then the accumulator can be manufactured, but difficult-to-weld materials like aluminum cannot be easily joined
Solution Approach 1:
The patent replaces welding processes with electromagnetic pulse joining, which forms metallurgical bonds through localized melting and fusion caused by intense electromagnetic forces. This alternative joining method works effectively with difficult-to-weld materials like aluminum and aluminum alloys, expanding material compatibility while maintaining manufacturing feasibility for sealing housing shells.
4Reliability
If clamping rings are used to mount diaphragms, then the diaphragm can be secured, but the design becomes more complex with additional components
Solution Approach 1:
The patent merges the diaphragm mounting function directly into the housing structure by creating integrated form-fitting connections between housing shells. The electromagnetic pulse joining process deforms the housing shells to create interference fits that securely hold the diaphragm in place, eliminating the need for separate clamping rings and reducing overall component complexity while maintaining mounting reliability.
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 method ensures a hydraulic accumulator with reliable tightness, high strength, and an undamaged surface, enabling a compact design with fewer bulky connections and allowing for the use of difficult-to-weld materials like aluminum, while maintaining a form-fitting and material-locking connection.
Implementation Method 1
A coil (40) is surrounded by a form fit to be produced on a component (3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i) made of electrically conductive material. A magnetic field is generated in order to induce currents in the component (3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i).
Implementation Method 2
The Lorentz force acting on a current-carrying conductor in a magnetic field can advantageously be used for form-fitting joining. Surprisingly, this force is so strong and precise that a metallic component with a considerable wall thickness can be defined and evenly deformed.
Implementation Method 3
A magnetic field is generated in order to induce currents in the component (3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i).
Data Source
Figure 1
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Figure 3
AI summary
The invention relates to a hydraulic accumulator, comprising a main body (2a, 2b, 2c, 2d, 2e, 2f, 2g, 2h, 2i) having a first component (3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i) and a second component (4a, 4b, 4c, 4d, 4e, 4f, 4g, 4h, 4i) that are connected to one another by positive engagement and/or material bonding, wherein the aim of the invention is to provide a hydraulic accumulator which, after problem-free manufacture, has a very reliable seal, a high strength, a surface that is as undamaged as possible, and a structure in the joining region of the components that is as rotationally symmetrical as possible. The invention is characterised in that at least one component (3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i, 4a, 4b, 4c, 4d, 4e, 4f, 4g, 4h, 4i) is deformed by a contactless shaping process in such a way that said component enters into positive engagement and/or material bonding with the other component (3a, 3b, 3c, 3d, 3e, 3f, 3g, 3h, 3i, 4a, 4b, 4c, 4d, 4e, 4f, 4g, 4h, 4i).