Hydraulic Unit Combining Pneumatic Drive and Ball Screw Pumping
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Solution Overview
Problem
Conventional hydraulic units face issues such as high electric energy consumption, noise generation, heat buildup, and mechanical wear due to constant operation of electric motors and metal-to-metal contact in hydraulic pumps, leading to inefficiencies and oil leakage.
Innovation Solution
A hydraulic unit combining a pneumatic cylinder and servomotor with a ball screw mechanism that uses compressed air to move a hydraulic plunger, reducing energy consumption and eliminating noise and heat through efficient oil pumping and storage in a pressure accumulator, minimizing metal contact and oil volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If electric motors continuously drive hydraulic pumps to send oil to the system, then the hydraulic actuators can be controlled and moved, but electric energy is wasted when actuators are idle
Solution Approach 1:
The system uses a periodic action principle by operating the hydraulic pump only when needed through sensor detection. The microprocessor-controlled system activates the pump based on actual hydraulic actuator operation requirements, replacing continuous operation with intermittent, demand-based operation. This eliminates energy waste during idle periods while maintaining actuator control functionality.
Solution Approach 2:
The system implements feedback control through sensors that detect the position and operation status of hydraulic actuators. This feedback information is processed by a microprocessor that controls the pump operation, ensuring the pump runs only when actuators are actively being moved. The feedback mechanism enables the system to respond to actual operational needs rather than operating continuously.
2Productivity
If hydraulic pumps continuously circulate oil, then hydraulic actuators can be operated, but heat is generated due to oil attrition and metal-to-metal contact
Solution Approach 1:
By replacing continuous pump operation with periodic, demand-driven operation, the system significantly reduces the total time that oil is being circulated and pressurized. This reduces the cumulative heat generation from oil attrition and mechanical friction. The pump operates only during actual actuator movement, minimizing thermal buildup in the hydraulic fluid.
Solution Approach 2:
The system converts the potential harm of continuous operation (heat generation) into a benefit by using sensor detection to intelligently control pump operation. The same operational monitoring that ensures productivity also prevents unnecessary heat generation by shutting down the pump when actuators are idle, turning a harmful continuous process into a beneficial intermittent one.
3Productivity
If hydraulic pumps operate continuously, then oil can be supplied to actuators, but noise is generated due to metal-to-metal contact in pump components
Solution Approach 1:
The system eliminates continuous noise generation by implementing periodic pump operation controlled by sensors. The pump runs only when actuators are actively being operated, creating silence during idle periods. This replaces the constant noise of continuous operation with intermittent, task-specific operation, significantly reducing overall noise exposure in the work environment.
4Productivity
If hydraulic pumps operate continuously with metal-to-metal contact, then oil can be pumped, but wear occurs and solid particles are released into the system
Solution Approach 1:
By operating the pump only when needed rather than continuously, the system reduces the cumulative wear on metal components. Less operating time means fewer cycles of metal-to-metal contact, reducing particle generation and component degradation. This extends system reliability while maintaining the necessary oil pumping function during actual operation.
Solution Approach 2:
The system turns the potential harm of continuous wear and particle generation into a benefit by using sensor-controlled intermittent operation. The same operational monitoring that ensures productivity also protects against wear by shutting down the pump during idle periods, converting a harmful continuous wear process into a beneficial protective mechanism.
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 achieves up to 90% savings in electric energy, significantly reduces noise and oil volume, maintains low oil temperature, and extends system lifespan by eliminating waste energy and attrition-related issues, creating a more efficient and comfortable working environment.
Implementation Method 1
pneumatic cylinder (15) that has a pneumatic plunger (12), separating the lower pneumatic chamber (14) from the upper pneumatic chamber (18)
Implementation Method 2
ball screw (29), which will receive torque from the servomotor (M) to turn clockwise and counter-clockwise, with the objective of displacing the hydraulic plunger (7) upward and downward
Implementation Method 3
hydraulic plunger (7) begins to draw oil from the oil reservoir (16)
Implementation Method 4
hydraulic pressure accumulator (25), where it will continue to be filled until the pneumatic plunger (12) reaches the end of the downward stroke
Data Source
AI summary
The present patent of invention relates to a hydraulic unit (U) with a pneumatic cylinder (15) that works jointly with a servomotor (M), together with a ball screw (29) to together move a hydraulic piston pump (8), made up of a hydraulic plunger (7), with related sealing elements to prevent oil leaks, noise, metal-on-metal attrition and loss of efficiency, that is moved upwards and downwards using a ball screw (29) and a pneumatic cylinder (15), jointly with a servomotor (M) which, when moved, pushes the pressurized oil outwards while filling the opposite hydraulic chamber with an oil suction movement, the pumped oil entering a hydraulic pressure accumulator (25), where it remains idle to be used when required and being supplied by the up/down movement of the piston, generating continuous pumping, which is automatically stopped when the hydraulic pressure accumulator (25) is full and has reached the predetermined hydraulic pressure.