Hydraulic Pump Automatic Cycling via Flow Sensing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Hydraulic pumps used to drive torque wrenches require repeated manual actuation to extend and retract the hydraulic cylinder, leading to operator fatigue and inefficiency, especially when dealing with multiple fasteners that need to be tightened or loosened.
Innovation Solution
A hydraulic pump with an automatic mode that applies the appropriate torque to a fastener with a single continuous actuation of an actuator and shuts down once the desired torque is achieved, utilizing a flow sensing manifold and microcontroller to automate the cycling of the torque wrench.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual actuation is used to extend and retract the hydraulic cylinder, then the operator has direct control over the torque application, but operator fatigue increases and efficiency decreases when dealing with multiple fasteners
Solution Approach 1:
The system performs automatic cycling of the hydraulic cylinder based on flow sensor feedback, allowing the system to serve itself by automatically extending and retracting the cylinder without requiring continuous manual actuation, thereby resolving the contradiction between operator control and productivity
Solution Approach 2:
The flow sensor provides feedback about hydraulic fluid movement to the controller, which automatically adjusts the cycling of the hydraulic cylinder accordingly, enabling the system to maintain proper torque application while operating autonomously to improve efficiency
2Manufacturing precision
If repeated actuation is required for each fastener, then precise torque control is maintained, but the operation becomes slow and time-consuming
Solution Approach 1:
The automatic cycling mechanism maintains continuous useful action by seamlessly extending and retracting the hydraulic cylinder based on flow feedback, eliminating idle time between actuations while maintaining precise torque control through the feedback loop
Solution Approach 2:
The system dynamically adjusts the cycling frequency and duration of the hydraulic cylinder based on real-time flow sensor feedback, optimizing the balance between maintaining precise torque control and reducing overall operation time
3Productivity
If automatic cycling is implemented, then operator fatigue is reduced and efficiency increases, but system complexity increases due to additional sensors and controllers
Solution Approach 1:
The flow sensor acts as an intermediary that provides simple, reliable feedback about hydraulic fluid movement, enabling automatic control without requiring complex sensing systems, thus achieving productivity improvement with minimal added complexity
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 automatic mode significantly reduces operator fatigue and increases efficiency by allowing the pump to automatically cycle the torque wrench, ensuring proper torque application and shutdown, thereby enhancing the speed and efficiency of the process.
Implementation Method 1
a flow sensor operatively connected to the flow sensing manifold and configured to detect flow of the hydraulic fluid through at least one of the retract and extend pathways
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A hydraulic flow sensing apparatus is provided. The apparatus includes: a manifold; a hole in the manifold in fluid communication with a fluid pathway; a poppet valve in the hole in the manifold configured to move when fluid in the pathway flows; and a proximity switch configured to detect movement of the poppet valve. A method of operating a hydraulic circuit may also be provided.