Hydraulic Tool Regenerative Extension for Two-Speed Crimping
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Solution Overview
Problem
Existing hydraulic tools lack the capability to operate at variable speeds and apply different forces based on the tool's state or the cutting operation, which limits their efficiency in crimping and cutting applications.
Innovation Solution
The hydraulic tool incorporates a hydraulic actuator cylinder with a piston that moves at two distinct speeds and applies different forces by utilizing a regeneration check valve and a pilot-operated valve to control fluid flow between chambers, allowing for efficient crimping and cutting operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If fluid is provided continuously to the first chamber at high flow rate, then the piston moves at high speed, but the force applied by the piston is reduced
Solution Approach 1:
The hydraulic system dynamically switches between two operational modes (speed mode and force mode) based on the crimping process requirements. The pilot-operated valve transitions the system from high-speed extension to high-force crimping, allowing the piston to operate at different speeds and forces during different phases of the crimping cycle.
Solution Approach 2:
The system changes the hydraulic parameters (flow rate and pressure) by switching between two fluid paths. In speed mode, high flow rate is provided to the first chamber. In force mode, the system redirects fluid flow to create high pressure, thereby changing the operational parameters from speed-oriented to force-oriented operation.
2Productivity
If the hydraulic system uses a single-speed operation, then the device complexity is reduced, but the productivity and efficiency for different crimping stages are compromised
Solution Approach 1:
The pilot-operated valve acts as an intermediary device that controls the transition between speed mode and force mode. It receives pilot pressure from the hydraulic supply line and uses this control pressure to switch the main fluid path, enabling two-speed operation without requiring two separate pumps or complex control systems.
Solution Approach 2:
The single hydraulic pump serves multiple functions by providing both high-flow low-pressure operation (for rapid extension) and high-pressure low-flow operation (for crimping). The pilot-operated valve enables this multi-functionality, allowing one pump to perform both speed and force generation tasks.
3Force
If high pressure is applied continuously to perform crimping, then the force is sufficient, but the time required for extension and positioning is increased
Solution Approach 1:
The hydraulic system employs periodic action by alternating between two distinct phases: a high-speed extension phase and a high-force crimping phase. The pilot-operated valve timing ensures that high pressure is applied only during the crimping phase, while the extension phase operates at lower pressure with higher flow rate, optimizing both speed and force application in sequence.
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 solution enables the hydraulic tool to efficiently perform crimping and cutting tasks by rapidly advancing the piston before engaging the cable and then applying a larger force for the operation, enhancing precision and efficiency.
Implementation Method 1
hydraulic actuator cylinder with a piston that moves at two distinct speeds and applies different forces by utilizing a regeneration check valve and a pilot-operated valve to control fluid flow between chambers
Data Source
AI summary
Embodiments of the invention provide a hydraulic tool including a hydraulic actuator cylinder, a piston, a fluid reservoir, a pump, a regeneration check valve, and a pilot-operated valve. The regeneration check valve is disposed in a regenerative extension fluid path that fluidly couples a first and second chamber of the hydraulic actuator cylinder. The pilot-operated valve is disposed in a power extension fluid path that fluidly couples the second chamber to a fluid reservoir.