Hydraulic Piston Insert Structure for Dead Volume Reduction
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Solution Overview
Problem
The efficiency of hydraulic piston machines is reduced due to the compressibility of water, which leads to decreased performance in pumping liquids.
Innovation Solution
A hydraulic piston machine design featuring an insert that extends out of the hollow piston, secured by pliable rings, reduces dead volume and prevents tilting, ensuring efficient fluid flow and minimizing wear by using a conical section and strategically placed pliable rings for secure positioning and fluid passage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the piston hollow is completely filled with insert material, then the dead volume inside the piston is reduced, but the liquid dead volume outside the piston cannot be reduced
Solution Approach 1:
The insert extends not only radially to fill the piston hollow but also axially beyond the piston end face into the pressure arrangement. This three-dimensional extension allows the insert to reduce dead volume in both the internal hollow and external channels simultaneously, addressing the limitation of conventional inserts that only fill the hollow cavity.
Solution Approach 2:
The liquid dead volume is extracted or removed from the system by having the insert material occupy the space in the channels and pressure arrangement. The insert effectively 'takes out' the harmful liquid dead volume that causes compressibility losses, replacing it with compressible solid material.
2Reliability
If the insert is secured at only one position in the hollow, then the structure is simple, but the insert may tilt under centrifugal forces
Solution Approach 1:
The securing function is extracted from a single complex anchoring system and distributed to multiple simpler securing positions. The insert is secured at both its front end and rear end, with each position providing independent stabilization, preventing tilting under centrifugal forces without requiring overly complex single-point anchoring.
3Ease of manufacture
If the section diameter is constant, then manufacturing is simple, but flow conditions for liquid are poor
Solution Approach 1:
The insert section has different diameters at different locations to optimize local functions. The larger diameter at the rear provides structural stability and securing space, while the smaller diameter at the front improves liquid flow conditions by reducing obstruction in the channel. This local differentiation of geometry optimizes both manufacturing and flow efficiency.
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 design enhances the efficiency of the piston machine by reducing dead volume, maintaining secure positioning of the insert, and allowing fluid flow for cooling, thereby improving performance and reducing wear while maintaining low costs.
Implementation Method 1
the insert is secured in the hollow at a first position and at a second position... the insert is secured in the first position axially and radially and secured in the second position radially only
Implementation Method 2
When the piston is arranged in a cylinder drum of an axial piston machine, there are centrifugal forces acting on the piston and likewise on the insert in the piston
Implementation Method 3
Although water is generally considered as incompressible fluid, it is in fact slightly compressible. The compressibility of water decreases the efficiency of the machine
Data Source
AI summary
A hydraulic piston machine is described comprising a piston (1) having a hollow (2) secured by a wall (3) and an insert (4) arranged in the hollow. Such a machine should have a high efficiency at low costs. To this end the insert (4) comprises a section (29) which extends out of the hollow (2).