Laser-Welded Working Cylinder Closures Without Threaded Joints
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Solution Overview
Problem
Existing working cylinders face challenges with high material consumption, complex machining processes, and reduced service life due to thread-based connections, which lead to increased costs and operational inefficiencies.
Innovation Solution
The working cylinder employs laser ring weld seams to connect closure parts to the cylinder tube, eliminating the need for threading and additional sealing, thereby reducing material thickness and machining requirements while ensuring a strong, fluid-tight connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If threading is used to connect closure parts to the cylinder tube, then the connection is secure and reliable, but the tube wall thickness must be significantly oversized to absorb forces during operation, leading to increased material consumption
Solution Approach 1:
The patent removes the threading process entirely from the connection method. Instead of cutting threads into the cylinder tube, the closure parts are connected through other means (such as welding or mechanical coupling) that do not require material removal, thereby eliminating the need for oversized tube walls to compensate for thread-induced weakening.
Solution Approach 2:
The patent replaces the mechanical threading system with an alternative connection method. The threading mechanism is substituted with a different joining technique that does not compromise the structural integrity of the cylinder tube, allowing for reduced material thickness while maintaining connection reliability.
2Reliability
If machining processes are used to create threads, then the connection is secure, but the manufacturing process requires high precision and is very demanding, increasing production complexity
Solution Approach 1:
The patent extracts the machining process entirely from the manufacturing sequence. By eliminating the need to machine threads, the production process becomes less demanding in terms of precision requirements and manufacturing complexity, while still achieving secure connections through alternative methods.
Solution Approach 2:
The complex mechanical machining process is replaced with a simpler connection method. The substitution eliminates high-precision machining requirements, reducing manufacturing complexity and making the production process more accessible and cost-effective.
3Ease of operation
If screw connections are used to connect closure parts, then the connection can be assembled and disassembled, but additional means must be provided to prevent the screw connection from loosening, increasing device complexity
Solution Approach 1:
The patent removes the screw connection system entirely, eliminating the need for anti-loosening measures such as lock nuts, thread-locking compounds, or other additional components. The connection method is replaced with one that inherently prevents loosening while maintaining assembly and disassembly capabilities.
4Reliability
If threading is used to connect closure parts, then the connection is secure, but the changing operating pressures result in dynamic loads on the threads, limiting their service life
Solution Approach 1:
The patent extracts the threading system from the connection method, eliminating the threads that are subject to dynamic loading from pressure changes. The alternative connection method used is not susceptible to the same fatigue and loosening issues, thereby extending the service life of the cylinder.
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 approach results in a more cost-effective, precise, and durable working cylinder with reduced material usage, improved axial concentricity, and enhanced operational safety by minimizing the risk of loosening and wear, while also eliminating the need for additional sealing components.
Implementation Method 1
Both closure parts are welded to the cylinder tube in each case by means of a laser welding process
Data Source
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AI summary
The invention relates to a working cylinder comprising a cylinder tube, a first closure part, a second closure part, and a piston unit, wherein the cylinder tube has a first cylinder tube end and a second cylinder tube end, the first closure part is arranged at the first cylinder tube end, the second closure part is arranged at the second cylinder tube end, the cylinder tube and the closure parts form a cylinder interior, the piston unit forms at least one working space in the cylinder interior, and the piston unit slidingly passes through the first closure part, characterised in that the first closure part is integrally connected to the cylinder tube by means of a first peripheral laser ring weld and the second closure part is integrally connected to the cylinder tube by means of a second peripheral laser ring weld, and the laser ring welds each form a fluid-tight sealing plane. At least one closure part has an axially opening, peripheral, concave receiving contour in which the cylinder tube engages, wherein the receiving contour radially overlaps the cylinder tube and the ring weld inclination angle alpha is 110 to 160 degrees.