Sensor-Controlled Hydraulic Tool to Prevent Ram Jamming
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Solution Overview
Problem
Existing powered hydraulic tools used by utility linemen and professional electricians face reliability issues in demanding conditions, such as jamming or dysfunction, which can slow progress and expose workers to unnecessary risks, and there is a need for tools that react to real-time variables for safer and more efficient operation.
Innovation Solution
A hydraulic tool equipped with an electric motor, pump, reservoir, chamber, ram, primary and secondary triggers, and a control system with sensors to manage hydraulic fluid flow, including a solenoid actuated valve and return spring, which adjusts operations based on real-time variables like pressure, temperature, current, and viscosity to ensure safe and efficient cutting or crimping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the pump continues to pump hydraulic fluid after the ram is fully extended or the tool is clamped around the work piece, then the cutting or crimping force is maintained and enhanced, but the tool may become jammed or dysfunctional
Solution Approach 1:
The control system continuously monitors the position of the ram and the state of the tool using sensors. When the ram reaches full extension or the tool is clamped around the work piece, the control system receives feedback signals and automatically adjusts or stops the pump operation to prevent over-pressurization and jamming, while maintaining sufficient cutting or crimping force.
Solution Approach 2:
The control system is pre-programmed with knowledge of the tool's operational limits and required forces. Before jamming can occur, the system proactively adjusts pump operation based on predetermined pressure thresholds and ram position feedback, preventing the harmful condition rather than reacting to it after it occurs.
2Ease of operation
If the tool is designed to be lighter weight and ergonomic for field use, then ease of operation is improved, but reliability may be compromised compared to heavier shop-use tools
Solution Approach 1:
The tool incorporates an automated control system that monitors its own operational state and adjusts hydraulic fluid delivery in real-time. This self-regulating capability ensures consistent performance and prevents malfunction regardless of the tool's size or weight, maintaining reliability while allowing for ergonomic, lightweight design suitable for field use.
3Reliability
If the control system automatically overrides user action on the primary trigger when a threshold condition is determined, then safety is improved by preventing jamming, but user control is reduced
Solution Approach 1:
The control system uses sensors to continuously monitor tool operation and compares actual conditions against predetermined safe operating thresholds. When feedback indicates a threshold condition (such as excessive pressure or incomplete ram extension), the system automatically overrides the trigger to prevent unsafe operation, while otherwise maintaining full user control during normal operation.
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 tool provides enhanced reliability and safety by automatically adjusting operations to prevent overextension or jamming, ensuring precise control and efficient completion of tasks under varying conditions.
Implementation Method 1
a solenoid actuated valve is in fluid communication with the chamber. The solenoid actuated valve opens upon being activated, and the chamber decompresses as the hydraulic fluid flows from the chamber to the reservoir.
Implementation Method 2
A return spring may be coupled to the ram, the return spring acting to retract the ram thereby forcing the reservoir fluid through the open solenoid actuated valve back to reservoir.
Implementation Method 3
the pump to move hydraulic fluid from the reservoir into the chamber thereby extending the ram
Data Source
AI summary
A hydraulic tool that executes a sequence of operations includes: a motor; a pump; hydraulic fluid driven by the pump; a chamber in fluid communication with the hydraulic fluid; a ram movably positioned at least partially in the chamber according to the hydraulic fluid and pressure thereof; a primary trigger configured to cause, upon actuation thereof, activation of the motor thereby causing: the pump to move hydraulic fluid from the reservoir into the ram chamber, extending the ram; a control system; and at least one sensor in communication the control system. When the primary trigger is user actuated and the ram is fully extended or the tool is clamped around a work piece, the pump continues to pump fluid, under at least partial control by the control system, until a threshold condition is determined by the at least one control system using the at least one sensor.