Hydraulic Pressing Tool Control via Pressure-Relief Valve Sensing
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Solution Overview
Problem
Existing pressing tools require manual control of hydraulic pumps, leading to inefficient energy use and uncertainty about the completion of the pressing process, as operators must maintain pressure until the process ends, risking insufficient workpiece compression.
Innovation Solution
A pressing tool with a hydraulic pump, electric motor, pressure-relief valve, and electronic control system, where a sensor monitors the pressure-relief valve's state and signals the control to manage the motor's operation, ensuring the required pressure is reached and power is conserved by automatically stopping the motor when the predefined pressure is achieved.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual control of hydraulic pump is used, then operator can control pressing process, but energy consumption increases and pressing completion is uncertain
Solution Approach 1:
The patent implements automatic control by monitoring the motor current and comparing it to reference values. When the current reaches a threshold indicating sufficient pressing, the system automatically stops the motor. This feedback mechanism eliminates manual intervention, ensures consistent pressing completion, and prevents unnecessary energy consumption by stopping the motor at the optimal moment.
Solution Approach 2:
The pressing tool performs self-monitoring and self-stopping through automated detection of pressing completion. The control system continuously monitors motor current, determines when pressing is sufficient, and autonomously stops the hydraulic pump motor, making the system self-sufficient without requiring operator judgment or continuous engagement.
2Use of energy by moving object
If operator releases push button early, then energy consumption decreases, but pressing may be insufficient
Solution Approach 1:
The system uses motor current monitoring as a feedback parameter to determine pressing completion. By comparing real-time current values against predetermined thresholds, the control system objectively determines when sufficient compression has been achieved, eliminating guesswork and ensuring consistent quality while optimizing energy usage.
Solution Approach 2:
The patent establishes predetermined current thresholds and control parameters before operation begins. These pre-set reference values encode the optimal pressing criteria, allowing the system to automatically execute precise control without requiring operator experience or judgment during the pressing process.
3Force
If motor runs continuously, then pressing force is maintained, but energy waste occurs
Solution Approach 1:
The motor operates in periodic cycles rather than continuously. The control system activates the motor to build pressing force, monitors the process through current feedback, and automatically stops the motor when the target pressing level is reached. This periodic operation pattern maintains necessary force while eliminating continuous energy waste.
Solution Approach 2:
The system applies pressing force beyond what might be minimally necessary, then automatically stops when a predetermined current threshold is reached. This approach ensures sufficient pressing is always achieved while preventing excessive energy consumption by limiting motor runtime to only what is necessary for adequate compression.
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 ensures complete and efficient pressing processes while minimizing energy consumption, as the motor operates only as needed, and provides reliable detection of the required pressure being reached, enhancing tool usability and power management.
Implementation Method 1
a hydraulic pump (27) for conveying a hydraulic fluid (70)
Implementation Method 2
a pressure-relief valve (50) which opens at a certain predefined pressure (Pv) of the hydraulic fluid (70)
Data Source
AI summary
A pressing tool for pressing workpieces is described. The pressing tool comprises a hydraulic pump for conveying a hydraulic fluid, an electric motor for driving the hydraulic pump, a working cylinder which is hydraulically connected to an outlet of the hydraulic pump, a pressure-relief valve which is hydraulically connected to the outlet of the hydraulic pump and which opens at a certain predefined pressure Pv of the hydraulic fluid, an electronic control for controlling the electric motor and a sensor 60 which monitors the state of the pressure-relief valve and emits a signal which describes the state of the pressure-relief valve to the electronic control. Furthermore, a method of operating such a pressing tool is described.