Integrated Linear Actuator Pump Assembly for Fail-Safe Hydraulic Control
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Solution Overview
Problem
Conventional linear actuator assemblies in harsh environments suffer from complexity, susceptibility to damage, and lack of fail-safe operation, leading to increased machine downtime and reduced reliability.
Innovation Solution
A compact and integrated linear actuator system with a variable-speed and/or variable-torque pump, controlled by a controller to adjust flow and pressure without additional flow control devices, and a fail-safe mode for abnormal operations, using a closed-loop configuration with integrated hydraulic cylinder and pump assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional hydraulic systems use separate components (motor, pump, cylinder, valves) connected by hoses and pipes, then the system can provide hydraulic actuation, but the system becomes large, complex, and susceptible to damage in harsh environments
Solution Approach 1:
The patent integrates the motor, pump, and hydraulic cylinder into a single unified actuator assembly. The motor is coupled directly to the pump which is integrated with the cylinder, eliminating the need for separate components and external fluid lines. This merging reduces system complexity and eliminates vulnerable connection points while maintaining full hydraulic actuation functionality.
Solution Approach 2:
The integrated actuator assembly serves multiple functions within a single compact unit: the motor provides power, the pump generates hydraulic pressure, and the cylinder delivers linear motion. This multi-functional design eliminates the need for separate dedicated components for each function, reducing overall system complexity and improving reliability.
2Productivity
If the motor and hydraulic pump are run at high speed to provide pressurized fluid, then the system can operate efficiently, but temperature builds up in the hydraulic fluid
Solution Approach 1:
The patent extracts the pump from its traditional separate location and integrates it directly with the motor and cylinder. This repositioning allows the pump to draw fluid directly from the cylinder's return line, creating a closed-loop system where fluid is continuously circulated and cooled by the motor housing, thereby managing temperature while maintaining operational efficiency.
3Ease of manufacture
If additional components like connecting shafts, hoses, pipes, and fittings are used to interconnect parts, then the system can be assembled, but the components become susceptible to damage or degradation in harsh working environments
Solution Approach 1:
The patent combines multiple separate components (motor, pump, cylinder, fluid lines) into a single integrated assembly where internal fluid passages replace external hoses and pipes. This eliminates vulnerable connection points and external fluid lines that are susceptible to damage in harsh environments, while the assembly can still be manufactured using standard processes.
4Ease of operation
If a variable-displacement hydraulic pump and directional flow control valve are used to control flow, then the hydraulic cylinder can be extended or retracted, but the system becomes more complex and requires additional components
Solution Approach 1:
The patent merges the functions of flow control and directional control into the integrated pump-cylinder assembly. The pump's variable displacement mechanism and the cylinder's porting are coordinated through the integrated design, eliminating the need for separate external flow control valves while maintaining full control capability for extending and retracting 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
Enhances reliability and reduces machine downtime by providing precise control and thermal stability, while minimizing the risk of cavitation and high fluid temperatures, ensuring safe operation even in harsh conditions.
Implementation Method 1
The linear actuators, e.g., a hydraulic cylinder, in linear actuator assemblies are used to cause linear movement... The motor drives the hydraulic pump to provide pressurized fluid from the fluid reservoir to the hydraulic cylinder
Implementation Method 2
the hydraulic pump to provide pressurized fluid from the fluid reservoir to the hydraulic cylinder in a predetermined manner, which in turn causes the piston rod of the cylinder to move within the body of the cylinder
Data Source
AI summary
A linear actuator system includes a linear actuator and an integrated pump assembly connected to the linear actuator to provide fluid to operate the linear actuator. The integrated pump assembly includes a pump with two fluid drivers, each fluid driver comprising a prime mover and a fluid displacement assembly to be driven by the prime mover such that fluid is transferred from a first port of the pump to a second port of the pump. The pump assembly also includes two valve assembles to isolate the pump from the system. The linear actuator system also includes a controller that establishes the pump in a normal mode of operation in which the prime movers are independently driven and switches to a fail-safe mode of operation in which only one prime mover is operated.