Hydraulic Power Tool Assembly With Auto-Return Overpressure Relief
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Solution Overview
Problem
Existing power tools with hydraulic systems face inefficiencies in fluid management, leading to potential damage and reduced operational safety due to uncontrolled hydraulic pressure and lack of effective pressure monitoring and control mechanisms.
Innovation Solution
A hydraulic drive assembly with a pump assembly, reservoir, cylinder, and auto-return valve system, coupled with a pressure sensor and tool controller, that monitors and regulates hydraulic pressure to prevent overpressure and automatically return the piston to a safe position, incorporating a baffle to diffuse fluid impact and a manual release mechanism for controlled fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If hydraulic pressure is increased to improve cutting power, then the cutting ability is enhanced, but the risk of overpressure damage and safety hazards increases
Solution Approach 1:
The system performs preliminary actions by pre-positioning the auto-return valve and pressure sensor to monitor and control hydraulic pressure before dangerous overpressure conditions occur. The valve is pre-configured to automatically redirect fluid flow when pressure thresholds are approached, preventing overpressure damage before it happens.
Solution Approach 2:
The pressure sensor provides continuous feedback on hydraulic pressure levels to the control system. This feedback loop enables real-time monitoring and automatic adjustment of the hydraulic system to maintain pressure within safe operational limits while maximizing cutting power when appropriate.
2Force
If hydraulic pressure is increased to improve cutting power, then the cutting ability is enhanced, but the operational safety decreases
Solution Approach 1:
The auto-return valve is pre-positioned and configured to activate before dangerous pressure levels are reached. The system establishes predetermined pressure thresholds and automatically responds by redirecting hydraulic fluid flow, ensuring safety actions are taken proactively rather than reactively.
Solution Approach 2:
The hydraulic system incorporates self-service safety mechanisms where the auto-return valve automatically regulates pressure without requiring external intervention. The system monitors its own pressure levels and self-corrects by diverting fluid flow when thresholds are exceeded, maintaining operational safety autonomously.
3Reliability
If pressure monitoring and control mechanisms are added to prevent overpressure, then safety is improved, but the device complexity increases
Solution Approach 1:
The pressure control system operates autonomously using the auto-return valve and pressure sensor that automatically monitor and regulate hydraulic pressure without requiring external control systems or complex intervention mechanisms. The system serves itself by detecting pressure conditions and automatically adjusting fluid flow accordingly.
Solution Approach 2:
The solution uses hydraulic principles and fluid dynamics to achieve pressure control through the auto-return valve's ability to redirect hydraulic fluid flow based on pressure conditions. This approach leverages the inherent properties of hydraulic systems to provide safety control without adding complex mechanical or electronic components.
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
Enhances operational safety and efficiency by preventing damage from overpressure, extending tool life, and ensuring safe operation through pressure regulation and automatic piston return, while providing timely service alerts to maintain tool functionality.
Implementation Method 1
The pump assembly thereby generates a flow of a hydraulic fluid from a reservoir to a cylinder through a inlet passageway
Implementation Method 2
a piston disposed in the cylinder and biased to a first position by a piston spring
Implementation Method 3
the auto-return valve is opened in response to reduction of the hydraulic pressure in the inlet passageway, thereby opening the outlet passageway and allowing the hydraulic fluid to flow from the cylinder to the reservoir
Implementation Method 4
a baffle supported in the reservoir
Data Source
AI summary
The present disclosure provides a power tool including a housing and a hydraulic drive assembly at least partially supported in the housing. The housing includes a handle that supports a switch that activates the tool. The hydraulic drive assembly includes a pump assembly operably coupled to the motor assembly, a reservoir configured to contain hydraulic fluid in fluid communication with the pump assembly and in which a baffle is supported, a cylinder in fluid communication with the pump assembly which supports an auto-return valve therein, and a piston disposed in the cylinder and biased to a first position by a piston spring. The pump assembly includes a manifold housing that at least partially defines an inlet passageway that fluidly communicates the pump assembly and the cylinder and supports an inlet check valve.