Hydraulic Unit Connection Body Segmented Composite Design
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Solution Overview
Problem
Existing hydraulic units face high production costs and complexity due to the need for a resilient metallic material for the connection body that supports both the electric motor and hydraulic pump, as well as hydraulic components, making simple production methods like die-casting impractical and leading to significant machining scrap and material waste.
Innovation Solution
The connection body is composed of two structural units, where one unit serves as a support for the electric motor and hydraulic pump, made from metallic material, and the other, exposed to lower loads, is produced using injection molding from plastic, such as glass-fiber reinforced polyamide, allowing for a composite structure that reduces production effort and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the connection body is made from resilient metallic material to support the electric motor and hydraulic pump, then the mechanical strength and stability are improved, but the production cost and device complexity increase due to complex machining and material costs
Solution Approach 1:
The connection body is divided into two separate structural units: a metallic support structure for mechanical strength and a plastic cover structure for housing and protection. This segmentation allows each component to be optimized for its specific function, with the metallic part providing structural integrity and the plastic part providing protective enclosure, thereby reducing overall production complexity compared to machining a complete metallic connection body.
Solution Approach 2:
The connection body uses a composite structure combining metallic material (for the support structure requiring strength) and plastic material (for the cover structure). This composite approach allows the metallic portions to provide necessary mechanical strength while the plastic portions reduce weight and machining requirements, ultimately lowering production costs and complexity.
2Strength
If the connection body is made from metallic material with complex shape, then the mechanical strength is improved, but the material cost increases due to large proportion of machining scrap
Solution Approach 1:
The connection body is segmented into a metallic support structure and a plastic cover structure. The metallic support structure is designed to provide mechanical strength with minimized material usage, while the plastic cover structure is produced through injection molding with near-net-shape capability, significantly reducing machining scrap and material waste compared to producing the entire connection body from metal.
Solution Approach 2:
The material parameter is changed from entirely metallic to a combination of metallic and plastic materials. The plastic cover structure is produced using injection molding processes that achieve near-net-shape manufacturing, minimizing the need for subsequent machining operations and thereby reducing material scrap and production costs.
3Ease of manufacture
If the connection body is made from plastic material, then the production cost and weight are reduced, but the mechanical strength and resilience are insufficient to support the electric motor and hydraulic pump
Solution Approach 1:
The connection body is segmented into a metallic support structure specifically designed to provide mechanical strength for mounting the electric motor and hydraulic pump, and a plastic cover structure that provides protective enclosure and housing functions. This segmentation allows the metallic portion to bear the mechanical loads while the plastic portion contributes to cost reduction and weight savings.
Solution Approach 2:
The connection body employs a composite material strategy where metallic material is used for the support structure requiring high strength and stiffness, while plastic material is used for the cover structure where lower mechanical requirements are acceptable. This composite approach optimizes the balance between mechanical strength, production cost, and weight.
4Stability of the object's composition
If the connection body is made as a one-piece component, then the structural integrity is improved, but the production simplicity and adaptability are reduced due to the need for resilient metallic material and complex machining
Solution Approach 1:
The connection body is divided into a metallic support structure and a plastic cover structure that can be manufactured separately and then assembled. This segmentation enables the metallic support structure to be produced using cost-effective processes for achieving structural integrity, while the plastic cover structure can be produced through injection molding, simplifying production and allowing for easier adaptation to different hydraulic requirements.
Data Source
Figure 1
Figure 2~3
AI summary
A hydraulic unit, in particular for supplying pressurized liquid to conveying and lifting mechanisms, comprising a tank (7) that is located at the end in relation to a main device axis (9), and functional components that are mounted on the tank (7) and consist in at least one hydraulic pump (1), a connecting element (5) and an electric motor (3) for driving the hydraulic pump (1), is characterized in that the connecting element (5) is composed of at least one structural unit (11) and at least one other structural device (13) and in that at least part of the one structural unit (11) is accommodated in the other structural device (13).