Piston-Cylinder Assembly Replacement for Fast On-Site Repair
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing repair methods for piston-cylinder units in working machines are time-consuming and costly, requiring complete disassembly and specialized tools, which can lead to increased downtime and risk of damage during the repair process.
Innovation Solution
A method where the piston rod, piston, and bearing head are removed as a single assembly from the cylinder housing and replaced with a premounted substitute assembly, allowing for on-site repair without disassembling the entire piston-cylinder unit, reducing the need for specialized tools and minimizing downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire piston-cylinder unit is removed and completely disassembled for repair, then defective components can be exchanged, but repair time and downtime increase significantly
Solution Approach 1:
The piston-cylinder unit is segmented into two main parts: the cylinder housing that remains mounted, and the removable assembly consisting of piston rod, piston, and bearing head. This segmentation allows repair work to be focused only on the necessary components while leaving the cylinder housing in place, thereby reducing repair time and downtime without compromising the completeness of component exchange.
Solution Approach 2:
The defective assembly (piston rod, piston, and bearing head) is extracted from the cylinder housing as a complete unit. This extraction allows for efficient replacement with a premounted substitute assembly, eliminating the need for complete disassembly and reassembly of the entire piston-cylinder unit, thus significantly reducing repair time while ensuring all defective components are replaced.
2Reliability
If complete disassembly is performed to exchange defective components, then all defective parts can be replaced, but the complexity of the repair process increases
Solution Approach 1:
The piston rod, piston, and bearing head are merged into a single removable assembly that can be exchanged as one unit. This merging simplifies the repair process by reducing the number of separate disassembly and reassembly steps, while still ensuring that all defective components within the assembly are replaced. The premounted substitute assembly is pre-assembled, further reducing repair complexity.
Solution Approach 2:
The substitute assembly is prepared in advance as a premounted unit with all necessary components (piston rod, piston, bearing head) already assembled and sealed. This preliminary preparation eliminates the need for complex on-site assembly operations, reducing repair process complexity while ensuring all defective components are properly replaced with a complete, pre-tested assembly.
3Reliability
If specialized tools are used for complete disassembly, then proper repair can be performed, but the availability and cost of tools increase
Solution Approach 1:
The repair process is segmented to require only the detachment of the removable assembly from the cylinder housing, which can be accomplished with basic tools. The complex disassembly operations are eliminated by designing the assembly to be removable as a complete unit, thereby improving tool availability while maintaining repair quality through the standardized assembly interface.
Solution Approach 2:
The assembly is designed to be self-contained and self-removable, allowing machine operators to perform the replacement without requiring specialized workshop tools. The connection between the removable assembly and cylinder housing is designed to be detachable with standard tools, enabling operators to service the system themselves and eliminating dependency on specialized tool availability.
4Reliability
If the piston-cylinder unit is completely removed for repair, then all components can be inspected, but machine downtime increases
Solution Approach 1:
The system is segmented into a stationary cylinder housing that remains mounted and a movable assembly (piston rod, piston, bearing head) that is removed and replaced. This segmentation allows the cylinder housing to stay in place, maintaining machine structure integrity, while the removable assembly is quickly exchanged, minimizing machine downtime and maximizing availability.
Solution Approach 2:
The removable assembly is extracted from the cylinder housing as a complete unit for replacement. This extraction allows for complete inspection and replacement of all components within the assembly (piston rod, piston, bearing head, seals) without removing the entire piston-cylinder unit from the machine, thereby maintaining high machine availability while ensuring thorough component inspection and replacement.
Data Source
AI summary
Disclosed is a method for repairing a piston-cylinder unit within a working machine or within an attachment, wherein a connection of the piston rod with the machine or implement structure is released and the piston rod, the piston and at least one bearing head is jointly removed from the cylinder housing as an assembly and replaced by a premounted substitute assembly consisting of piston rod, piston and at least one bearing head.