Hydraulic Power Tool Pressure Feedback for Safe High-Load Operation
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Solution Overview
Problem
Existing power tools with hydraulic systems lack efficient pressure management and safety features to prevent damage and ensure safe operation, particularly in high-pressure applications.
Innovation Solution
A hydraulic drive assembly with a pump assembly, reservoir, cylinder, and auto-return valve system, along with a pressure sensor and tool controller, that manages hydraulic pressure and automatically disables the tool when thresholds are exceeded to prevent damage and ensure safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If hydraulic pressure is increased to improve cutting performance, then productivity increases, but the risk of tool damage and safety hazards increases
Solution Approach 1:
The system incorporates a pressure sensor that continuously monitors hydraulic pressure and provides feedback to the control board. When pressure exceeds the predetermined threshold, the control board automatically de-energizes the motor, preventing further pressure increase and potential tool damage. This closed-loop feedback mechanism enables the tool to operate at high pressures for improved productivity while automatically preventing dangerous pressure levels.
2Productivity
If hydraulic pressure is increased to improve cutting performance, then productivity increases, but safety hazards increase
Solution Approach 1:
The pressure sensor provides continuous monitoring and feedback to the control board, enabling automatic safety shutdown when pressure exceeds predetermined thresholds. This ensures high-pressure operation for productivity while preventing safety hazards through automated protection.
Solution Approach 2:
The system performs self-protection by automatically detecting excessive pressure conditions and shutting down the motor without requiring external intervention. The control board monitors pressure levels and independently de-energizes the motor when thresholds are exceeded, providing built-in safety functionality.
3Reliability
If a pressure relief valve is used to manage hydraulic pressure, then safety is improved, but hydraulic fluid loss increases
Solution Approach 1:
The electronic pressure monitoring system provides precise feedback control, de-energizing the motor when pressure reaches the predetermined threshold. This prevents excessive pressure buildup that would require relief valve activation, thereby maintaining safety while preventing hydraulic fluid loss through more accurate pressure management.
Solution Approach 2:
The system replaces the mechanical pressure relief valve approach with an electronic control system using a pressure sensor and control board. This substitution allows for more precise pressure control by de-energizing the motor at the exact threshold, eliminating the need for mechanical relief valve discharge and preventing hydraulic fluid loss.
4Device complexity
If manual pressure monitoring is used, then device complexity is reduced, but measurement precision and response time deteriorate
Solution Approach 1:
The pressure sensor provides continuous, precise digital feedback to the control board, enabling accurate real-time pressure monitoring and automatic response. This electronic feedback system achieves superior measurement precision and response time compared to manual monitoring, while the overall system remains relatively simple in design.
Solution Approach 2:
The system replaces manual pressure monitoring with an electronic pressure sensor and control board system. This substitution provides automated, precise, and rapid pressure detection and response, eliminating the imprecision and delay inherent in manual monitoring while adding minimal complexity to the overall tool design.
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 effectively manages hydraulic pressure, preventing tool damage and ensuring safe operation by automatically disabling the tool when pressure limits are reached, thereby extending tool life and protecting the operator.
Implementation Method 1
The pump assembly thereby generates a flow of a hydraulic fluid from a reservoir to a cylinder through a inlet passageway
Implementation Method 2
a piston disposed in the cylinder and biased to a first position by a piston spring
Implementation Method 3
the auto-return valve is opened in response to reduction of the hydraulic pressure in the inlet passageway, thereby opening the outlet passageway and allowing the hydraulic fluid to flow from the cylinder to the reservoir
Data Source
AI summary
The present disclosure provides a power tool including a housing and a hydraulic drive assembly at least partially supported in the housing. The housing includes a handle that supports a switch that activates the tool. The hydraulic drive assembly includes a pump assembly operably coupled to the motor assembly, a reservoir configured to contain hydraulic fluid in fluid communication with the pump assembly and in which a baffle is supported, a cylinder in fluid communication with the pump assembly which supports an auto-return valve therein, and a piston disposed in the cylinder and biased to a first position by a piston spring. The pump assembly includes a manifold housing that at least partially defines an inlet passageway that fluidly communicates the pump assembly and the cylinder and supports an inlet check valve.