Hydraulic Cylinder Lock Nut Positioning and Sensing
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Solution Overview
Problem
Existing hydraulic cylinder systems face challenges in maintaining load stability and safety during lifting and lowering due to manual lock nut operation, which can lead to uneven stress distribution and potential damage from sudden pressure losses, requiring an automated position sensing and locking system for synchronized operation.
Innovation Solution
A hydraulic cylinder position sensing and locking system that automatically maintains the position of a lock nut to prevent plunger retraction upon hydraulic pressure loss, using a drive unit and controller to rotate the lock nut based on distance sensor feedback, ensuring the lock nut remains within a desired range, and incorporating a synchronous system for multiple actuators to maintain balanced lifting and lowering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual lock nut operation is used, then device complexity is reduced, but reliability deteriorates due to risk of sudden pressure loss and load damage
Solution Approach 1:
The system automatically monitors plunger position and adjusts the lock nut without manual intervention. The controller continuously receives position signals from the sensor and commands the drive unit to rotate the lock nut as needed, making the system self-regulating and eliminating the need for operators to manually adjust locking mechanisms during operation.
Solution Approach 2:
A position sensor continuously monitors the plunger's axial position and feeds this information back to the controller. The controller processes this feedback signal and adjusts the lock nut position accordingly, creating a closed-loop control system that maintains reliable load support by dynamically responding to position changes.
2Productivity
If manual lock nut adjustment is required, then ease of operation is maintained, but loss of time increases due to personnel needing to access and adjust lock nuts
Solution Approach 1:
The automated system performs lock nut adjustment without requiring operator intervention. The controller automatically commands the drive unit to rotate the lock nut based on sensor feedback, eliminating the time operators would spend accessing, assessing, and manually adjusting lock nuts during lifting operations.
Solution Approach 2:
The manual mechanical adjustment process is replaced with an automated electromechanical system. The drive unit, controlled by an electronic controller receiving sensor input, substitutes for manual operator actions, significantly reducing the time required for lock nut adjustment and improving overall operational efficiency.
3Stability of the object's composition
If lock nut is not continuously positioned, then ease of operation is improved, but stress distribution deteriorates due to uneven load support
Solution Approach 1:
The position sensor continuously monitors plunger position and provides feedback to the controller, which adjusts the lock nut to maintain proper stress distribution. This closed-loop control ensures that the lock nut is continuously positioned to support the load evenly, preventing uneven stress concentrations that could damage the load or equipment.
Solution Approach 2:
The system dynamically adjusts the lock nut position in real-time based on changing load conditions and plunger position. Rather than using a fixed lock nut position, the system adapts continuously to maintain optimal stress distribution, making the operation simple while ensuring load stability through automated dynamic adjustment.
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 automated locking and synchronized operation, preventing load damage from pressure losses and ensuring balanced stress distribution, enhancing safety and efficiency in lifting and lowering heavy loads.
Implementation Method 1
The plunger is axially moveable relative to the cylinder in an extension direction and a retraction direction by selective supply of hydraulic fluid under pressure to the hydraulic cylinder
Implementation Method 2
a distance sensor that provides a signal that has an axial spacing value indicative of an axial spacing between the lock nut and the hydraulic cylinder
Data Source
AI summary
The invention provides for a hydraulic cylinder position sensing and locking system that automatically maintains the position of a lock nut (36) that engages a plunger (16) on a hydraulic actuator such that if hydraulic pressure is lost, the lock nut prevents retraction of the plunger into the hydraulic cylinder (14). The hydraulic cylinder position sensing and locking system also provides for a position sensing feature that allows for the calculation of the axial stroke position of the plunger based on rotary movement of the lock nut. In addition, the invention provides for a synchronous hydraulic cylinder position sensing and locking system and methods of using both the hydraulic cylinder position sensing and locking system as well as the synchronous hydraulic cylinder position sensing and locking system.