Integrated Hydraulic Linear Actuator for Fail-Safe Flow Control
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Solution Overview
Problem
Conventional linear actuator assemblies in harsh environments suffer from complexity, susceptibility to damage, and lack of fail-safe operation, leading to increased machine downtime and reduced reliability.
Innovation Solution
A compact, integrated linear actuator system with a variable-speed and/or variable-torque pump, controller, and sensor assemblies for precise control of hydraulic fluid flow and pressure, featuring a normal and fail-safe mode of operation, and a closed-loop configuration without additional flow control devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional linear actuator assemblies use separate components (hydraulic cylinder, pump, motor, reservoir, valves) connected by hoses and pipes, then the system can provide necessary hydraulic functions, but the device complexity increases and reliability decreases in harsh environments
Solution Approach 1:
The patent integrates the hydraulic pump, motor, and control valves into a single compact assembly unit. The pump and motor are coupled together with the pump inlet fluidically coupled to the motor output, creating an integrated drive assembly that eliminates the need for separate components and external hoses, thereby reducing complexity and improving reliability.
Solution Approach 2:
The integrated assembly serves multiple functions simultaneously: the motor drives the pump to generate hydraulic pressure, the assembly includes integrated flow control valves for directional control, and the entire unit acts as both a power source and fluid delivery system, reducing the number of separate components needed.
2Productivity
If the motor and hydraulic pump are run at high speed to provide pressurized fluid, then the hydraulic cylinder can be controlled effectively, but temperature builds up in the hydraulic fluid
Solution Approach 1:
The patent introduces a fluid reservoir as an intermediary component that receives excess hydraulic fluid from the cylinder. This reservoir acts as a thermal buffer, allowing the fluid to cool down before being重新pumped, thereby managing temperature buildup while maintaining system productivity.
Solution Approach 2:
The system discards excess fluid to the reservoir where it can cool, and then recovers this cooled fluid for continued operation. This cyclic process of discarding hot fluid to the reservoir and recovering cooled fluid from the reservoir manages thermal accumulation while maintaining continuous operation.
3Ease of manufacture
If separate components are spaced apart and interconnected with connecting shafts, hoses, and pipes, then the system can be assembled with standard components, but the components are susceptible to damage or degradation in harsh working environments
Solution Approach 1:
By merging the pump, motor, and control valves into a single integrated assembly, the patent eliminates external hoses and connecting pipes that are vulnerable to environmental damage. The integrated design protects internal fluid passages from external harsh conditions while maintaining ease of manufacture through modular assembly.
4Ease of operation
If a variable-displacement hydraulic pump and directional flow control valve are included to control flow, then the hydraulic cylinder can be precisely controlled, but the system becomes larger and more complex
Solution Approach 1:
The patent combines the variable-displacement pump mechanism and directional flow control valves within the same integrated assembly. The motor shaft is coupled to the pump mechanism, and the valves are incorporated into the same housing, providing precise flow control while maintaining a compact, unified structure rather than separate components.
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
Enhances reliability and reduces machine downtime by providing a compact, durable design that maintains stable fluid temperatures and ensures safe operation even in harsh conditions.
Implementation Method 1
the motor drives the hydraulic pump to provide pressurized fluid from the fluid reservoir to the hydraulic cylinder
Implementation Method 2
a hydraulic cylinder, in linear actuator assemblies are used to cause linear movement... the motor drives the hydraulic pump to provide pressurized fluid... to the hydraulic cylinder in a predetermined manner, which in turn causes the piston rod of the cylinder to move
Data Source
Figure 1
Figure 1A
Figure 2
AI summary
Industrial machine, comprising: a first structural element; a second structural element; a linear actuator assembly that extracts and retracts a piston assembly, the linear actuator assembly including a linear hydraulic actuator and an integrated hydraulic pump assembly conjoined with the linear hydraulic actuator to provide hydraulic fluid to operate the linear hydraulic actuator, the integrated hydraulic pump assembly and a controller to exclusively adjust at least one of a flow and a pressure to the linear hydraulic actuator to a desired set point.