Machine Press Cylinder Accumulator Base Pressure
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Solution Overview
Problem
Existing machine presses face challenges in optimizing design size and structural complexity, leading to high manufacturing costs, particularly in large and powerful machines, where maintaining a consistent base pressure higher than environmental pressure is difficult without excessive chamber requirements.
Innovation Solution
The machine press incorporates a cylinder accumulator with a hydraulic chamber and a high-pressure gas accumulator, where the piston unit is urged by a pressurized fluid chamber connected to a high-pressure gas accumulator, allowing for a smaller design size and increased flexibility, enabling a compact hydraulic drive system with reduced chamber requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional pressure accumulator is used to maintain base pressure in the hydraulic system, then the base pressure can be maintained, but the chamber requirement becomes excessively large and the structure becomes complex
Solution Approach 1:
The hydraulic system is segmented into two independent pressure sources: a main hydraulic pump and a secondary high-pressure gas accumulator. This segmentation allows the gas accumulator to be much smaller since it only needs to maintain base pressure during idle periods, not supply all hydraulic demands.
Solution Approach 2:
The high-pressure gas accumulator is pre-charged with gas at a pressure slightly above the required base pressure. This preliminary action ensures that when the hydraulic system is idle, the gas pressure automatically maintains the base pressure in the hydraulic lines without requiring a large accumulator chamber.
2Reliability
If a conventional pressure accumulator is used to maintain base pressure, then pressure stability is achieved, but the device complexity and manufacturing costs increase
Solution Approach 1:
The system separates the functions of pressure generation (main pump) and pressure maintenance (gas accumulator). This functional segmentation simplifies each component's design requirements and reduces overall system complexity.
Solution Approach 2:
A gas-charged accumulator is used instead of a traditional hydraulic accumulator. The compressibility of gas provides automatic pressure regulation and base pressure maintenance through pneumatic principles, reducing the need for complex hydraulic control mechanisms.
3Volume of stationary object
If the active face of the gas accumulator on the piston unit is made small compared to the hydraulic chamber face, then a smaller high-pressure gas accumulator can be used, but the pressure generation efficiency may be reduced
Solution Approach 1:
The gas accumulator is designed to provide only the minimal excessive pressure needed to maintain base pressure (typically 0.5-2 bar above hydraulic pressure), not full operating pressure. This partial action allows a much smaller accumulator volume while still achieving the pressure maintenance function.
Solution Approach 2:
The system changes the pressure parameter of the gas accumulator to operate at a slightly elevated base pressure rather than full operating pressure. This parameter change allows the use of a smaller accumulator with reduced force requirements on the piston, directly reducing accumulator size.
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 ensures a reliable base pressure higher than environmental pressure across all operating phases with a smaller high-pressure gas accumulator, reducing costs and complexity, and allows for more compact and flexible hydraulic drive systems, even in large machine presses.
Implementation Method 1
a high-pressure gas accumulator with a volume of approximately 0.3 to 0.5 L, a hydraulic drive unit with an alternating volume on the order of 10 L can be held constantly at a base pressure between 2 and 3 bar
Implementation Method 2
a cylinder accumulator with a hydraulic chamber and a high-pressure gas accumulator, where the piston unit is urged by a pressurized fluid chamber connected to a high-pressure gas accumulator
Data Source
AI summary
In a machine press with a lower and an upper tool support, a closed hydraulic drive system acts upon the upper tool support. This system has at least one hydraulic drive unit, which includes at least one hydraulic cylinder-piston unit and at least one hydraulic assembly acting upon this unit and supplied from a storage reservoir. A base pressure above environmental pressure constantly prevails in the storage reservoir. The storage reservoir is designed as a cylinder store with a hydraulic chamber defined by a cylinder and a piston unit displaceably guided therein. The piston unit is acted upon on its side functionally opposite the hydraulic chamber by a hydraulic fluid chamber which for its part is connected to a high-pressure gas store. The active surface of the hydraulic fluid chamber on the piston unit is small compared to the active surface of the hydraulic chamber on the piston unit.