Hydraulic Tool Sequence Valve Speed Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Hydraulic tools lack efficiency in moving at variable speeds and applying different forces effectively, which is crucial for operations like cutting and crimping, as existing systems do not seamlessly transition between rapid advancement and precise, high-force applications.
Innovation Solution
A hydraulic tool design featuring a piston with a partially hollow configuration and a sequence valve that allows pressurized fluid to flow into two chambers at different pressures, enabling the piston to extend at varying speeds and apply different forces based on resistance encountered, such as rapidly advancing before slowing down for precise cutting or crimping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the hydraulic piston advances rapidly to reach the object, then the productivity is improved, but the manufacturing precision deteriorates because the tool cannot apply controlled force for precise cutting or crimping
Solution Approach 1:
The hydraulic system dynamically transitions between two operating modes: a first mode with rapid piston advancement for quick jaw closure, and a second mode with controlled, slower advancement for precise cutting or crimping. This dynamic switching resolves the contradiction by adapting the system behavior to the specific operational phase.
Solution Approach 2:
The system changes hydraulic parameters (flow rate and pressure) between two distinct states. In the first state, high flow rate enables rapid piston movement for productivity. In the second state, reduced flow rate and increased pressure provide controlled movement and high force for manufacturing precision. This parameter transformation resolves the speed-precision trade-off.
2Manufacturing precision
If the hydraulic system applies high force for precise operations, then the manufacturing precision is improved, but the productivity deteriorates due to slower operation speed
Solution Approach 1:
The hydraulic system employs periodic or sequential action by alternating between two distinct operational phases: a rapid advancement phase for productivity, followed by a controlled high-force phase for precision. This periodic switching allows the system to achieve both high speed and high precision at different times in the operational cycle.
3Device complexity
If the system uses a single-speed hydraulic actuator, then the device complexity is reduced, but the adaptability deteriorates because it cannot effectively handle both rapid advancement and controlled force application
Solution Approach 1:
The hydraulic actuator is segmented into two functional parts: a first chamber for rapid advancement and a second chamber for controlled high-force operation. The sequence valve segments the hydraulic fluid flow, directing it to different chambers based on pressure thresholds. This segmentation allows the system to achieve multi-speed capability while maintaining relatively simple overall structure.
Solution Approach 2:
The sequence valve acts as an intermediary device that automatically controls the switching between rapid and controlled motion modes based on pressure conditions. This intermediary component enables adaptability without requiring complex electronic controls or multiple independent actuators, thus balancing versatility with simplicity.
4Productivity
If the hydraulic piston advances quickly, then the productivity is improved, but the force application deteriorates because insufficient pressure is available for precise cutting or crimping
Solution Approach 1:
The system transforms hydraulic parameters between two states: in the first state, high flow rate with lower pressure enables rapid piston movement. In the second state, reduced flow rate with significantly increased pressure provides both controlled speed and high force for cutting or crimping. This parameter transformation resolves the speed-force contradiction.
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 design enhances the tool's efficiency by allowing rapid advancement followed by controlled, high-force operations, ensuring precise cutting or crimping with reduced risk of over-pressure situations through a controlled hydraulic circuit and safety mechanisms like a burst disk.
Implementation Method 1
a sequence valve configured to block the pressurized fluid from flowing into the second chamber of the hydraulic actuator cylinder until pressure of the pressurized fluid exceeds a threshold pressure value
Implementation Method 2
a pump configured to provide pressurized fluid... When the tool is triggered the pump provides the pressurized fluid to a hollow portion of the piston, causing the piston to extend
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
An example tool (100) includes a hydraulic actuator cylinder (108); a piston (200) slidably accommodated within the hydraulic actuator cylinder, where the piston includes a piston head (203A) and a piston rod (203B) extending from the piston head along a central axis direction of the hydraulic actuator cylinder, the piston head divides an inside of the hydraulic actuator cylinder into a first chamber (210A) and a second chamber (210B), and the piston rod is disposed in the first chamber and configured to move one or more jaws of the tool; a pump (104) configured to provide pressurized fluid; and a sequence valve (120) configured to block the pressurized fluid from flowing into the second chamber of the hydraulic actuator cylinder until pressure of the pressurized fluid exceeds a threshold pressure value.