Piston-Cylinder Sensor Sealing for Leak-Free Removal
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Solution Overview
Problem
Existing piston-cylinder units face challenges in assembly and disassembly efforts, component variety, and stress on piston movement sensors due to high fluidic pressures and the need for precise positioning and alignment, which complicates the integration and removal of the sensor housing without leaking hydraulic fluid.
Innovation Solution
The piston movement sensor is fluidically separated from the pressure chamber using a sealing element, and a positioning and alignment element ensures accurate placement and orientation within the transverse bore, allowing for secure attachment and easy removal while maintaining the seal, utilizing a dielectric lens or collimator for signal alignment and focusing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the piston motion sensor is integrated in the cylinder head with fluidic separation, then the assembly and disassembly effort is reduced and the sensor housing stress is reduced, but the fluidic sealing complexity increases
Solution Approach 1:
The cylinder head is segmented into a sensor region and a hydraulic fluid region by the sealing element. The sealing element creates a fluidic barrier that separates the transverse bore (sensor housing area) from the pressure chamber, allowing independent assembly and disassembly of the sensor while maintaining hydraulic sealing.
Solution Approach 2:
The sealing element acts as an intermediary component between the sensor housing and the hydraulic fluid system. It provides the necessary fluidic separation while allowing the sensor to function independently, reducing the complexity of integrating sensors into high-pressure hydraulic environments.
2Measurement precision
If the piston motion sensor is positioned in the transverse bore, then the measurement accuracy is improved, but the positioning and alignment precision requirements increase
Solution Approach 1:
The transverse bore is pre-formed in the cylinder head with precise geometry and positioning. This preliminary structural preparation ensures that when the sensor housing is installed, it automatically achieves the correct alignment and position for accurate piston measurement, reducing the need for post-installation adjustment.
Solution Approach 2:
The transverse bore serves multiple functions: it provides structural support, defines the sensor positioning, establishes alignment references, and maintains fluidic separation. This multi-functionality reduces the number of separate components needed and simplifies the overall positioning system.
3Ease of repair
If the sensor housing is made removable, then the ease of repair and maintenance is improved, but the risk of hydraulic fluid leakage increases
Solution Approach 1:
The sealing system is segmented into distinct sealing interfaces: one between the sealing element and the cylinder head, and another between the sealing element and the sensor housing. This segmentation allows the sensor housing to be removable while maintaining reliable sealing at each interface through dedicated sealing elements.
Solution Approach 2:
The sealing element is designed with inherent sealing capacity and tolerance compensation features that cushion against misalignment and wear. This beforehand cushioning ensures that even with repeated assembly and disassembly, the hydraulic fluid sealing remains reliable without requiring perfect precision each time.
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 solution enhances the assembly and disassembly efficiency, reduces stress on the sensor housing, and ensures precise measurement accuracy by maintaining the hydraulic seal and allowing for the use of a single sensor across different piston-cylinder unit dimensions with minimal signal attenuation.
Implementation Method 1
utilizing a dielectric lens or collimator for signal alignment and focusing
Implementation Method 2
utilizing a dielectric lens or collimator for signal alignment and focusing
Implementation Method 3
The piston movement sensor is fluidically separated from the pressure chamber using a sealing element
Implementation Method 4
The piston motion sensor emits a sensor signal. This signal travels from the piston motion sensor through the pressure chamber to the piston or a piston rod. The sensor signal is reflected by the piston or piston rod.
Data Source
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AI summary
The invention relates to a piston-cylinder unit (1). A piston motion sensor (28) is arranged in a transverse bore (27) of a cylinder head (4) of the piston-cylinder unit (1). According to the invention, the transverse bore (27) is separated from a pressure chamber (33) that acts on a piston (7) of the piston-cylinder unit (1). This separation can be achieved by sealing a collimator (35) arranged in the beam path of a sensor signal against a sensor signal channel (26) via a sealing element (37). The seal allows the housing of the piston motion sensor (28) to be removed from the transverse bore (27) without the fluid from the pressure chamber (33) escaping into the environment. The piston-cylinder unit (1) according to the invention is used, for example, in a work machine, construction machine, agricultural machine, maritime machine, wheel loader, excavator, tipper truck, crane, forklift truck or lifting platform.