Hydraulic Pump Barrel Spline Insert Remanufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Hydraulic pumps in construction and heavy machinery experience rapid wear, leading to inefficiency and failure, resulting in wasted investment in non-worn components when discarded, necessitating effective salvage techniques and design modifications for remanufacturing.
Innovation Solution
The method involves machining new splines into the barrel of a hydraulic pump, using a spline insert with heat-treated internal splines to replace worn splines, and rebuilding the yoke's tab with a wear-resistant button to restore original functionality and extend the pump's service life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydraulic pumps are discarded after wear, then the pump can be replaced with a new unit, but the investment in non-worn components is lost
Solution Approach 1:
The pump is divided into worn components (splines, tab) and non-worn components (barrel, yoke, pistons, cylinders). Only the worn segments are replaced while the functional segments are retained and reused in the remanufactured pump.
Solution Approach 2:
Worn components (splines and tab) are discarded and replaced with new ones, while non-worn components are recovered and reused. This recovers the investment in non-worn components and enables cost-effective remanufacturing.
2Reliability
If worn components are replaced with new ones, then the pump reliability is restored, but the cost of remanufacturing increases
Solution Approach 1:
Only the worn components (splines and tab) are replaced rather than the entire pump. This partial replacement action restores reliability while minimizing remanufacturing costs by retaining all functional components.
Solution Approach 2:
The methodology discards only the worn components and recovers all non-worn components for reuse. This selective approach restores pump functionality while maintaining cost-effectiveness by recovering the majority of the original component investment.
3Reliability
If the entire pump is remanufactured, then all components are restored to like-new condition, but the cost and time required increase significantly
Solution Approach 1:
The pump is segmented into worn and non-worn components. Only the worn segments undergo replacement and restoration procedures, while non-worn segments skip the remanufacturing process and are used as-is, significantly reducing the remanufacturing cycle time.
Solution Approach 2:
The remanufacturing process applies partial action by processing only the worn components rather than the entire pump. This selective remanufacturing restores reliability where needed while minimizing the time and resources required for the overall remanufacturing process.
4Reliability
If splines are machined new in the barrel, then the worn splines are replaced, but the complexity of the remanufacturing process increases
Solution Approach 1:
The worn splines are extracted from the barrel through machining removal. This extraction of the worn element allows for its replacement with new splines, restoring reliable engagement while containing the complexity to a focused machining operation rather than a complete disassembly and reassembly process.
5Strength
If the tab is rebuilt with a wear-resistant button, then the wear resistance is enhanced, but the manufacturing steps increase
Solution Approach 1:
Instead of rebuilding the entire tab, a wear-resistant button is applied locally to the specific area of the tab that experiences wear. This local quality enhancement provides the necessary wear resistance while minimizing the manufacturing steps by avoiding complete tab replacement or extensive machining of the entire tab component.
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
This approach allows for cost-effective remanufacturing by replacing only worn parts, saving 40% of the new pump barrel's cost and 15% of the yoke's cost, while enhancing durability and extending the pump's service life.
Implementation Method 1
providing an insert, the insert having a second central bore having internal splines formed on an internal surface of the second central bore, the internal splines adapted for engaging external splines formed on a drive shaft
Data Source
AI summary
A hydraulic pump can be remanufactured to save the investment in its components that are not seriously worn or failed. Some of the worn components, such as the pump barrel and yoke, can be salvaged by replacing or rebuilding the worn features. In particular, a worn internal spline on the pump barrel can be replaced by a spline insert that is threaded to the pump barrel and includes a new internal spline. A worn actuation tab on a yoke for contacting an actuating piston can be replaced by adding a new tab wear button.