Modular Hydraulic Device Design for Faster Component Replacement
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Solution Overview
Problem
Existing hydraulic devices with rotating hydraulic agents, such as valve adjusters, peristaltic pumps, or gear pumps, are difficult to repair as they consist of integrated components that require disassembly of all connections for maintenance, leading to increased costs and time for repairs.
Innovation Solution
Designing the hydraulic device with rotatable hydraulic agents, an electric motor drive, and a gearbox where the drive, hydraulic agents, and gears are individual functional units that can be easily disconnected, replaced, and reconnected, allowing for modular repair without needing to replace the entire device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the hydraulic device is designed as an integrated system with all components permanently connected, then the structural stability and reliability are improved, but the ease of repair deteriorates as all connections must be disassembled for maintenance
Solution Approach 1:
The hydraulic device is divided into separate functional modules (hydraulic means, drive, transmission) that are detachably connected. Each module can be independently removed and replaced without disassembling the entire system, resolving the contradiction between structural stability and ease of repair.
Solution Approach 2:
The connection between modules is designed to be dynamically changeable - permanently stable during operation but easily detachable during maintenance. The detachable connection mechanism allows the system to switch between a stable integrated state and a separable maintenance state.
2Reliability
If the entire hydraulic device is replaced when a component fails, then the reliability is restored, but the loss of time and resources increases due to complete system replacement
Solution Approach 1:
By segmenting the hydraulic device into independent modules with detachable connections, only the faulty module needs to be replaced rather than the entire system. This significantly reduces repair time and resource consumption while restoring reliability.
Solution Approach 2:
The modular design enables selective replacement of only the defective component or module, while the remaining functional modules are recovered and retained for future use, reducing waste and repair time.
3Ease of repair
If the hydraulic device is designed as a modular system with detachable connections, then the ease of repair is improved, but the device complexity increases due to additional connection interfaces
Solution Approach 1:
The segmentation into modular components with standardized detachable connections improves ease of repair. The additional connection interfaces are minimized and standardized to reduce the complexity increase, creating a balanced design where maintenance benefits outweigh the added structural complexity.
Data Source
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AI summary
A hydraulic system comprises rotatable hydraulic elements such as a valve actuator or a peristaltic pump, an electric motor as a drive, and a gearbox between the drive and the hydraulic elements, wherein the hydraulic elements have at least two water-carrying ports. According to the invention, the drive, hydraulic elements, and gearbox are designed as individual functional units and detachably connected to one another as a complete functional unit in the form of the hydraulic system. The detachable connection is advantageously achieved by means of screws.