Modular Pneumatic Cylinder Stages for Adjustable Force Output
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Solution Overview
Problem
Existing pneumatic cylinders are designed for a specific force and are costly to produce, with limited flexibility in adjusting the force after manufacturing.
Innovation Solution
A modular pneumatic cylinder design featuring multiple stages with adjustable force capabilities, where additional or removal of stages allows operation within a wide pressure range (1 bar to 20 bar), using compressed air and a spring mechanism for stroke control, and components made of metal, plastic, or a combination for reduced weight and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a pneumatic cylinder is designed for a specific force, then the manufacturing cost is high, but the flexibility to adjust force after manufacturing is limited
Solution Approach 1:
The pneumatic cylinder is divided into multiple identical modular stages that can be stacked axially. Each stage contains a piston, piston rod, and sealing elements. By varying the number of stages (e.g., 2 to 6 stages), different force outputs are achieved without redesigning the entire cylinder, thus reducing manufacturing costs while maintaining force adjustability.
Solution Approach 2:
The force output of the pneumatic cylinder is adjusted by changing the number of active stages rather than modifying the dimensions or materials of individual components. This parameter change approach allows the same modular components to produce different force levels (e.g., 2 stages for lower force, 6 stages for higher force), providing versatility without increasing manufacturing complexity.
2Adaptability or versatility
If multiple cylinder stages are provided, then the force can be adjusted, but the device complexity increases
Solution Approach 1:
The cylinder is segmented into identical modular stages with standardized interfaces. Each stage is a self-contained unit with a piston, piston rod, and sealing elements. This segmentation allows complex force adjustment capabilities to be achieved through simple repetition of standardized modules, thereby managing device complexity through modularity and standardization.
Solution Approach 2:
The modular stages are arranged in a nested or stacked configuration where each stage contains similar sub-components. The piston rods of inner stages are connected to the piston of outer stages, creating a compact nested structure. This nesting principle allows multiple stages to be integrated in a space-efficient manner while maintaining ease of assembly and disassembly.
3Strength
If cylinder stages are made of metal, then the strength and durability are improved, but the weight increases
Solution Approach 1:
The pneumatic cylinder employs composite material construction where critical load-bearing components (such as the piston rod and connection elements) are made of metal for strength, while non-critical components (such as the piston body and housing) are made of plastic or polymer materials. This composite approach reduces overall weight while maintaining necessary strength and durability for the application.
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
Enables flexible force adjustment and reduced production costs, with a compact design suitable for various applications, including motor spindles, by allowing easy assembly and disassembly of stages and using compressed air for efficient operation.
Implementation Method 1
pressurizing the pneumatic cylinder leads to a stroke of the piston rod
Implementation Method 2
capable of being pressurized with compressed air
Data Source
AI summary
The invention relates to a modular pneumatic cylinder (1) comprising multiple cylinder stages (4), a cylinder base (2), and a cylinder head (3). An axial longitudinal bore (5) is provided which runs between the cylinder base and the cylinder head and leads to a piston rod (8) in the cylinder base (2) and which is designed to receive a securing means (7). Disc-shaped cylinder stages (4) are arranged concentrically about the bore (5), each cylinder stage comprising a piston (10), which annularly surrounds the bore (5), and a piston disc (9), which extends radially from the piston (10) and to which compressed air can be applied. The pistons (10) of the cylinder stages (4) are in operative engagement with the piston rod (8) such that applying pressure to the pneumatic cylinder (1) leads to a stroke movement of the piston rod (8).