Mechanically Lockable Force-Building Cylinder for Low-Energy Rapid Motion
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Solution Overview
Problem
Hydraulic presses with coupled cylinders for force-building and rapid movements require excessive hydraulic fluid movement, leading to high power consumption and valve loads, especially when smaller cylinders are used for rapid movements.
Innovation Solution
An electro-hydrostatic drive system with a hydro-machine of variable volume and/or rotational speed, driven by an electric motor, featuring a first larger cylinder for force-building and a second smaller cylinder for rapid movements, where the moveable carrier plate is connected to both cylinders, and a clamping apparatus allows the first cylinder to be clamped or unclamped from the pillar to optimize fluid flow during different phases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If all cylinders are coupled to move over the same distance, then the force-building movement can be achieved, but excessively high power consumption and valve loads occur during rapid movement
Solution Approach 1:
The system segments the cylinder functions by separating the force-building cylinder (first cylinder) from the rapid movement cylinder (second cylinder). The moveable carrier plate is connected to both cylinders, but only the second cylinder is coupled to the moveable carrier plate for rapid movement, while the first cylinder remains mechanically isolated during this phase. This segmentation allows each cylinder to perform its specific function independently, eliminating the need to move large volumes of hydraulic fluid through the first cylinder during rapid movement, thus reducing power consumption.
Solution Approach 2:
The system dynamically changes the mechanical connection configuration between cylinders and the moveable carrier plate based on the operation phase. During rapid movement, the second cylinder is coupled to the moveable carrier plate while the first cylinder is decoupled. During force-building movement, the coupling is reconfigured. This dynamic reconfiguration optimizes system performance for each specific operation phase.
2Force
If a larger cylinder is used for force-building movement, then sufficient force can be generated, but high power consumption occurs when this cylinder is also moved during rapid movement
Solution Approach 1:
The system assigns different cylinder sizes to different functions: the first (larger) cylinder is dedicated to force-building movement, while the second (smaller) cylinder handles rapid movement. By segmenting the functions and using a smaller second cylinder for rapid movement, the volume of hydraulic fluid that needs to be moved is minimized, reducing energy loss while maintaining sufficient force capability through the larger first cylinder when needed.
Solution Approach 2:
The system applies local quality by optimizing cylinder selection for specific functions. The smaller second cylinder is specifically designed and positioned for rapid movement applications where minimal fluid displacement is needed, while the larger first cylinder is optimized for force-building where high force is required. Each cylinder's characteristics are locally optimized for its specific function.
3Force
If the first cylinder is mechanically locked during force-building movement, then stable force can be applied, but the system becomes more complex with additional clamping mechanisms
Solution Approach 1:
The system introduces a clamping apparatus as an intermediary mechanism that provides mechanical locking between the first cylinder and the pillar during force-building movement. This intermediary component enables stable force application by preventing unwanted movement of the first cylinder, while maintaining system modularity and controllability through hydraulic actuation of the clamping mechanism.
Solution Approach 2:
The clamping apparatus is actuated hydraulically, using the existing hydraulic system to control the mechanical locking and unlocking of the first cylinder. This hydraulic actuation provides precise control of the clamping force and allows for easy engagement and disengagement of the mechanical lock, managing the added complexity through the use of the established hydraulic control infrastructure.
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 configuration significantly reduces energy consumption during rapid movements by minimizing hydraulic fluid movement in the larger cylinder, enhancing overall energy efficiency and system performance.
Implementation Method 1
a hydraulic drive (10) having a closed hydraulic circuit, which has, when run, a positive pressure above atmospheric pressure and which, by means of the hydro-machine (50), can pressurize either the first or the second cylinder chamber (120, 130, 220, 230) of the first cylinder (100) and/or the first or the second cylinder chamber (220, 230) of the second cylinder (200)
Implementation Method 2
a hydro-machine with variable volume and/or rotational speed, driven by an electric motor, for providing a volume-flow of a hydraulic fluid
Data Source
AI summary
An electro-hydrostatic drive for realizing a rapid movement and a force-building movement, comprising a hydro-machine with variable volume and/or rotational speed, driven by an electric motor, for providing a volume-flow of a hydraulic fluid, a first cylinder with a housing, a piston, a cylinder rod, and a first and a second cylinder chamber, a second cylinder with a piston, a cylinder rod, and a first and a second cylinder chamber, a moveable carrier plate, a pillar, and a clamping apparatus to clamp and/or unclamp the first cylinder to the pillar, where the hydraulic drive has a closed hydraulic circuit, which has, when run, a positive pressure above atmospheric pressure and which, by utilizing the hydro-machine, can pressurize either the first or the second cylinder chamber of the first cylinder and/or the first or the second cylinder chamber of the second cylinder. The moveable carrier plate is connected both to the first cylinder and to the second cylinder. For the force-building movement, the first cylinder is clamped, by the clamping apparatus, to the pillar and one cylinder chamber of the first cylinder is pressurized with the hydraulic fluid, and for the rapid movement, the first cylinder is unclamped, by the clamping apparatus, from the pillar and one cylinder chamber of the second cylinder is pressurized with the hydraulic fluid.