Pressure Intensifier Connection Bore Design
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Solution Overview
Problem
Existing pressure intensifiers face challenges in efficiently filling and emptying the high-pressure chamber due to small connecting line cross-sections, requiring complex valve systems and leading to potential contamination and increased cycle times, which results in higher investment costs and reduced operational reliability.
Innovation Solution
A pressure intensifier design with a connection bore in the high-pressure chamber wall, positioned just above the bottom dead center of the high-pressure piston, allowing for a larger filling bore and eliminating the need for additional valve devices, enabling faster filling and reduced cycle times by using a second pumping device with reduced capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a small cross-section connecting line is used to connect the high-pressure chamber to the component, then the device structure is compact, but the filling time increases and productivity decreases
Solution Approach 1:
The patent divides the connection system into two separate connections: a first connection for the second medium (hydraulic fluid) with larger cross-section for fast filling, and a second connection for the first medium (process fluid) with smaller cross-section for compact structure. This segmentation allows each connection to be optimized for its specific function, resolving the contradiction between compact structure and fast filling.
2Reliability
If a valve device is added to prevent pressure medium from escaping or entering the supply line, then reliability improves, but device complexity increases
Solution Approach 1:
The patent extracts and eliminates the non-return valve from the system by utilizing the natural pressure differential between the high-pressure chamber and the supply line. The physical arrangement and pressure conditions inherently prevent backflow, removing the need for additional valve components and reducing system complexity while maintaining reliability.
Solution Approach 2:
The system uses its own operating conditions (pressure differential) to automatically prevent medium escape or backflow into the supply line. The high pressure in the chamber naturally prevents inflow from the supply line, and the physical configuration prevents outflow during compression, making the system self-regulating without external valve control.
3Device complexity
If the connection is positioned close to the component, then the structure is compact, but impurities can be washed into the high-pressure chamber causing functional impairments
Solution Approach 1:
The patent applies different connection positions for different media: the first connection for the second medium is positioned away from the component to prevent contamination, while the second connection for the first medium is positioned close to the component for compact structure. This local differentiation of connection qualities resolves the contradiction between compactness and contamination prevention.
4Productivity
If a second pumping device with larger capacity is used to reduce filling time, then productivity increases, but investment costs increase
Solution Approach 1:
The patent dynamically switches between two connections during operation: using the first connection (larger cross-section) for fast filling when productivity is prioritized, and the second connection (smaller cross-section) when compact structure is prioritized. This dynamic utilization allows a smaller pumping device to achieve variable filling speeds, eliminating the need for an oversized pump while maintaining productivity flexibility.
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 reduces investment costs, enhances operational reliability, and shortens cycle times, allowing for more efficient processing of components with reduced risk of contamination, particularly beneficial in industrial series production.
Implementation Method 1
The low-pressure chamber is connected to a first pump device, which applies pressurized medium to the pressure surface of the low-pressure piston
Implementation Method 2
the pressure surface of the high-pressure piston has a reduced surface area compared to the pressure surface of the low-pressure piston. The high-pressure chamber of the pressure booster housing is at least indirectly connected to the component to be machined via a connecting line
Data Source
Figure 1
AI summary
The invention relates to a pressure intensifier (10), having a pressure-intensifier housing (11), in which a low-pressure piston (15) with a first pressure surface (18) is arranged in the pressure-intensifier housing (11), which low-pressure piston (15) delimits a low-pressure region (22) in a low-pressure region (20), having a high-pressure piston (16) which has a second pressure surface (19), which is smaller than the first pressure surface (18), and delimits a high-pressure chamber (35) in the pressure-intensifier housing (11), wherein the low-pressure piston (15) is coupled to the high-pressure piston (16), wherein the first pressure surface (18) is connected to a first pumping device (30) which loads the first pressure surface (18) with a first medium (24), wherein the high-pressure piston (16) can be moved between a bottom dead centre (UT) and a top dead centre (OT), wherein the high-pressure chamber (35) can be connected at least indirectly via a connecting line (36) with a smaller cross-sectional area than the second pressure surface (19) to a surface of a component (1) to be processed, and having a second pumping device (40) for a second medium (37), which second pumping device (40) is connected at least indirectly to the high-pressure chamber. It is provided according to the invention that the second pumping device (40) has a connector (38) which opens into the high-pressure chamber (35) of the pressure-intensifier housing (11).