Hydraulic Intensification Cylinder for Precise High-Force Control
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Solution Overview
Problem
Pneumatic intensification cylinders are expensive to operate and require continuous compressed air supply, while servoelectric actuators face challenges with mechanical complexity, size, and programming complexity, and linear servomotors lack sufficient force.
Innovation Solution
A hydraulic pressure cylinder system with a working cylinder and intensification cylinder, utilizing a pump, valves, and a controller to coordinate piston movements, enabling precise control and pressure amplification without compressed air, using hydraulic fluid for efficient force generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If pneumatic intensification cylinders are used, then force amplification is achieved, but operating cost increases due to continuous compressed air supply
Solution Approach 1:
The patent transitions from pneumatic to hydraulic intensification, using hydraulic fluid instead of compressed air. The hydraulic intensifier cylinder receives pressurized hydraulic fluid through a directional control valve, which is more cost-effective and energy-efficient than continuous compressed air supply while achieving the same force amplification effect through fluid pressure transmission.
Solution Approach 2:
The system changes the working medium parameter from gas (compressed air) to liquid (hydraulic fluid). This parameter change enables more efficient energy transmission and reduces operating costs, as hydraulic systems can maintain pressure more efficiently and allow for easier energy recovery through regenerative circuits.
2Force
If servoelectric actuators with ball or roller screw are used, then sufficient thrust is provided, but device complexity and size increase
Solution Approach 1:
The patent employs a hydraulic intensifier cylinder with piston and rod mechanism instead of mechanical ball or roller screw systems. This hydraulic approach provides equivalent or superior thrust capability while significantly reducing mechanical complexity, as it eliminates the need for precision ball screws, roller screws, and associated mechanical transmission components.
Solution Approach 2:
The invention extracts and eliminates the complex mechanical transmission elements (ball screws, roller screws) from the system, replacing them with a direct hydraulic actuation mechanism. This extraction of unnecessary mechanical complexity while retaining the essential force-generation function results in a simpler, more reliable system.
3Ease of operation
If servoelectric actuators are used, then control integration is improved, but setup and maintenance difficulty increases
Solution Approach 1:
The hydraulic intensifier system with directional control valve and pressure relief valve provides inherent mechanical simplicity that facilitates easier setup and maintenance. While control integration is maintained through electronic control of the directional valve, the overall system requires less complex calibration and fewer specialized maintenance procedures compared to servoelectric actuators with precision mechanical components.
4Measurement precision
If linear servomotors are used, then control precision is improved, but force output is insufficient
Solution Approach 1:
The patent merges the advantages of hydraulic force amplification with electronic control precision by combining a hydraulic intensifier cylinder with an electronically controlled directional valve. This hybrid approach achieves both high force output through hydraulic pressure intensification and precise control through electronic valve actuation, overcoming the limitations of linear servomotors that cannot deliver sufficient force.
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 system provides precise control over force and position, reduces mechanical complexity, and enhances operational reliability with a broader range of output forces, eliminating the need for compressed air and simplifying setup and maintenance.
Implementation Method 1
A pump is configured to provide a pressurized hydraulic fluid to the pressure cylinder
Implementation Method 2
A pressure relief valve is arranged in overpressure circuit, the pressure relief valve is configured to open from a normally closed position to communicate fluid from the advance working chamber to the retract passage when the advance working chamber reaches an undesired threshold
Data Source
AI summary
A pressure cylinder includes a working cylinder and an intensification cylinder that is divided by a separator block. A working piston is arranged in the working cylinder and connected to a working rod that extends to an end portion. An intensification piston and an intensification rod are arranged in the intensification cylinder. A pump is configured to provide a pressurized hydraulic fluid to the pressure cylinder. A fluid reservoir is configured to supply a hydraulic fluid to the pump. An overpressure circuit fluidly connects the advance working chamber and the retract passage, a pressure relief valve is arranged in overpressure circuit, the pressure relief valve is configured to open from a normally closed position to communicate fluid from the advance working chamber to the retract passage when the advance working chamber reaches an undesired threshold.